Holden Commodore VB

HOLDEN
COMMODORE
VB SERIES
SERVICE MANUAL
SECTION INDEX
FOREWORD
00 GENERAL INFORMATION
and LUBRICATION
BODY , SHEET METAL,
Thi s Manual co ntai ns desc ripti ons, specifica tion s and

01 RADIATOR GRILLE
and BUMPER BARS
se rvi ce p rocedu res for Holden Commodo re VB Se ri es VENTILATION , HEATING
vehicles.
02 and AIR CONDITIONING
Di ag nosis, main tenance , maj o r and min or se rvice ope rat-

ions are desc rib ed. However sin ce eng in e, transmission ,
fron t brake and rea r axle assemblies are simila r to those
03 FRONT SUSPENSION
used in oth er G MH vehi cles, no maj o r se rvice repair and

REAR SUSPENSION ,
overhau l procedures are given for th ese assembli es , and
reference should be made to existin g Se rvi ce Manuals as
detail ed in th e appropriate sec tions of th is publi ca tion .
04 REAR AXLES and
PROPELLER SHAFT
Th e sec ti on Ind ex on this page enables th e user to qui ckly

05 BRAKES
locate any desired sec ti on . At th e beginning of eac h sec ti on

contai ning more than one maj or subj ect is a Tab le of
Conten ts, wh ic h gives th e pag e number on whi c h eac h
maj or subj ec t begi ns. An Index is placed at th e beg inning
06 ENGINES
of eac h maj or subj ect within th e sec ti on.

07 CLUTCH and TRANSMISSIONS
Summari es of Spec ial Too ls, wh en required, are found at

th e end of maj or secti ons. Spec ifications co ve rin g vehi c le
components are also presented at th e rea r of eac h sec ti on.
08 FUEL TANK and
EXHAUST SYSTEM
All info rm ati on, illustrati ons and speci fica ti ons co ntain ed in
th is Man ual are ba sed on th e latest prod uct inform ati on
09 STEERING
avai lab le at th e tim e of publi ca ti on approval. Th e right is

res erv ed to make c hang es at any tim e with out notice . 10 WHEELS and TYRES
EFF ECTIV E JANUARY, 1979

12 ELECTRICAL
SERVIC E MA NUAL NO. M38145

I.S.B.N. 0 86836 016 3
PRIN T ED IN AUSTRALIA
GENERAL MOTORS-HOLDEN'S SALES PTY. LIMITED

SERVICE DEPARTMENT
CO PYR I GHT - GE N ERAL MOTORS - HOLDE N 'S SALES PTY. L TO.

Repr oduc t ion in wh o le o r in pa r t pro hibited wi t ho ut writt en app r oval
l
GENERAL INFORMATION & LUBRICATION Ou-0 1
SECTION 00
GENERAL INFORMATION AND LUBRICATION
CONTENTS OF THIS SECTION
Subject Pag e
GENERAL INFORMATION ............................................ 00-01
LUBRICATION ................................................................. 00-07
I
GENERAL INFORMATION
INDEX
Subj ect Page Subject Page
MODEL AVAILABILITY & BASE EQUIPMENT ........... 00 -01 GENERATOR (ALTERNATOR) .............................. 00-03
EXTERIOR DIMENSIONS ................................................ 00-02 IGNITION DISTRIBUTOR ......................................... 00-03
ENGINE DATA .................................................................. 00-02 STARTER MOTOR .................................................... 00-03
SERIAL NUMBERS .......................................................... 02-02 TRANSMISSION NUMBER LOCATION ................. 00-03
SERIAL NUMBER LOCATIONS ..................................... 00-02 Manual ................................................................. 00-03
IDENTIFICATION PLATE LOCATIONS ........................ 00-02 Trimatic ................................................................ 00-03
VEHICLE IDENTIFICATION NUMBER PLATE ..... 00-02 Turbo Hydramatic ............................................. 00-03
BODY & OPTION IDENTIFICATION PLATE ........ 00-02 TORQUE WRENCH SPECIFICATIONS ........................ 00-05
Model ................................................................... 00-02 ISOLATION OF BATIERY DURING ELECTRICAL
Body ..................................................................... 00-02 REPAIRS ......................................................................... 00-05
Trim ...................................................................... 00-03 JACKING PRECAUTIONS .............................................. 00-05
Paint ..................................................................... 00-03 VEHICLE HOIST LOCATIONS ....................................... 00-05
Top ....................................................................... 00-03 TOWING OR PUSHING TO START ENGINE .............. 00-05
Engine, Transmission, Rear Axle .................. 00 -03 MANUAL TRANSMISSION ...................................... 00-05
SAFETY COMPLIANCE PLATE ............................. 00-03 AUTOMATIC TRANSMISSION ................................ 00-05
VEHICLE SERIAL NUMBER ................................... 00-03 JUMP START WITH AUXILIARY BATIERY ........ 00-05
ENGINE NUMBER LOCATION ............................... 00-03 VEHICLE TOWING .................................................... 00-06
L6 Engine ............................................................ 00-03 Safety ................................................................... 00-06
V8 Engine ........................................................... 00 -03
MODEL AVAILABILITY & BASE EQUIPMENT
MO DE L TRANSMI SS ION
BODY CU R B AXLE
STYL E WE IG HT EN G I NE RATIO TYRES WH EELS
SH I FT
N U MBER NAM E ( EST IMATED) TYPE :1
L OCAT I ON
4 SPEED
8VK69 COMMODORE 1219 kg 2.85 3.55
M A NU AL
SLOTT ED
CR78S 14
STEEL
SEDAN CO MM ODORE
8V L69 1224 kg 3.3 FLOOR 3.08
4 DOOR 'SL'
AUTOMATIC
'TRIMATIC'
STY L ED
COMMODORE
8VX69 1365 kg 4 .2 2.78 BR60H1 5 CAST
'S L/E' ALLOY
00-02 GENERAL INFORMATION & LUBRICATION
EXTERIOR DIMENSIONS
WHEEL TREAD TREAD TURNING

MODELS LENGTH WIDTH HEIGHT
BASE (FR ONT) (REAR) CIRCLE
8VK69
10. 15m
4705mm 1451mm 1417mm
(K ER B TO KERB)
8VL69 1722mm 137 1mm 2668 mm
10.8m
(WALL T O WALL)
8VX69 4729mm 1449mm 1422mm
ENGINE DATA
ENGINE DESIGNATION 2.8 5 3.3 4.2 5.0
PISTON D ISP.
NOM. - Cu. in s. 173 202 253 308
PISTON DISP.
NOM .- Cu . cc 2838 3298 4142 5044
COMP. RATIO : 1 9.2 9.2 9.4 9.4
NUMBER CY LIND ER S 6 6 8 8
BORE I STROKE - in s. 3.500 X 3.00 3. 625 X 3.25 3.625 X 3.062 4.004 X 3.062
- mm 88.900 X 76.200 92.075 X 82.550 92.075 X 77.775 101 .60 X 77 .775
TAXABLE H.P.
R AC or SAE 29. 4 3 1.5 42.0 51.2
K.W. D IN
@ R.P .M. 64 @ 4000 (M) 66 @ 3600 (M) 87 @ 4000 (S ) 114 @ 4000 (S)
71 @ 3800 (A) 96 @ 4400 (D ) 125 @ 4200 (D)
TORQUE DIN
@ R.P.M. 198 @ 2000 (M) 221 @ 2100 (M) 271 @ 2000 (S) 344 @ 2200 (S)
213 @ 2000 (A) 275 @ 2400 (D) 352 @ 2600 (D)
(M) MANUAL TRANSMISSION (S) SINGLE EXHAUST

(A) AUTOMAT IC TRANSMI SS ION (D) DUAL EXHAUST
SERIAL NUMBERS
When co mpiling Warranty Claims , Product and Field Se r- BODY & OPTION IDENTIFICATION PLATE
vice Reports etc ., it is essential to quote the 'V.I.N. ' Vehicl e
Attached to upper front panel - right sid e. Refer Fig . 0-3 for
Identification Numbers, which are located on a plate in the
plate details.
centre of the upper front panel (see Fig . 0- 1). Th e se rial
numbers all ocated to th e following materi als or assem bli es Thi s plate contains th e .following information :
must also be quoted if th ey are being rep orted .
Model
SEAIAL NUMBER LOCATIONS The model number is a combination of letters and numbers
identifying the body model and style.
VEHICLE IDENTIFICATION NUMBER PLATE
Attached to th e upp er front panel - centre locati on. Refer Body.
Fig . 0-2 for plate detail s. The body number is a num eri ca l referen ce followed by a
GENERAL INFORMATION & LUBRICATION 00-03
suffix letter whi ch denotes plant at whi ch body was man - ENGINE NUMBER LOCATION
ufactured; i.e, M - Melbourn e.
L6 Engine
Trim.
Stamped on pad above engine mounting bosses , ri gh t side.
The trim numbers represent th e exteri c; r paint colour
co mbinati on and trim co mbination . V8 Engine
Stamped on pad at top front, left side of cylinder an d case .
Paint.
Th e paint numbers represen t th e exterior paint material and
co lour id entifi ca ti on of th e basic or lower colour.
GENERATOR(ALTERNATOR)
Top. Model number on circ umference of rear end housing .
Th e top numbers rep resent the exteri or paint material and
colo ur id entifi ca ti on of the roof or upper section of the body IGNITION DISTRIBUTOR
wh en it differs from the basic co lour. Model number on metal body of distributor below low
tension lead.
Engine, Transmission, Rear Axle.
Identification opti on codes are only used when either en- STARTER MOTOR
gin e, tran smi ss ion and / or rear axle differ from that al- Model number on circumference of centre housin g.
loca ted as standa rd to a parti c ular model.
TRANSMISSION NUMBER LOCATIONS

SAFETY COMPLIANCE PLATE
Attached to upper front panel - left side . Refer Fig . 0-4 for Manual
plate details.
3 & 4 Speed All Synchromesh . Number on rear end of
Thi s plate co ntain s the Australi an Design rule numbers built transmission case.
into th e vehi cle. It also indi cates the numbers of occupants
th e veh icle is designed to ca rry and month and year vehic le Trimatic
was produced. On plate attached to lower front, left side of case .
VEHICLE SERIAL NUMBER Turbo Hydramatic

Stamped on upper front panel ri ght sid e. Refer Fi g. 0-5 for On plate attached right side of transmission , forward of
detail s. governor.
BODY & OPTION IDENTIFI CAT ION

PLATE
VEHICLE IDENTIFICATION
PLATE
RIVET
SAFETY COMPLIANCE - FRONT PANEL

PLATE - UPPER
SECTION A
Figure 0-1
Identification Plate Locations
HOLDENPRODUCT~
BODY STYLE
(SEDAN}
~
l ~
I YEAR OF BUILD
H = 1978, J = 1979
l _ _ _ r : : ; C T I O N SEQUENC E
8L69LHJ600025B
MODE L "SL" J
ENGI NE SIZE 202 H C Jy L PRODUCTION PLANT
L L AST LETTE R OF
SER I ES CODE ' VB'
Figure 0-2
Vehicle Identification Number Plate
THIS VE HI CL E WAS MANU FACTURE D BY

GE N ERA L MOTOR S-HO L DEN ' S LIMITED
TO COMPLY WITH AUSTRALIAN DE SI GN RU L ES NOS .
GE N ERAL ~i OTORS - HOLDEN'S LIMITED
1,2,3A , 4C,5 B, 6 , 7,8, 10B, 11 , 12, 14, 15, 16, 18 ,20 ,
CORRE~?ON D E NCE MUST BEAR THESE NUMBERS
2 1, 22A, 23 ,24,25A, 27A, 28,29,3 1, 34
M ODEL ; VB8VL69 HOLDEN
BODY N O. : 62 1423M VB CO MMO DORE SEDA N
TR IM : 1442- 63X
P.AiNT : 567 - 30518 10- 78 AVB000103M
GVW Kg SE ATIN G CAP . 5
TO P: 568-30521
ENG . L14 TR ANS . M40 RR.AXL E GU 4 THIS PLATE IS AFFIXED WITH THE A PPR OVAL OF THE
MA DE IN AUSTRALIA AUSTRALIAN MOTOR VEHI CLE CERTIFICATION BOARD
Figure 0-3 Figure 0-4

Body & Option Identification Plate Safety Compliance Plate
1. DESIGN RULE COMPLIANCE LETTER

2. VEHICLE SER I ES 'VB'
3. ASSEMBLY PLANT SERIAL NUMBER
4 . ASSEMBLY PLANT I DENTIFICATION
' M ' MELBOURNE
, 5. REQUIREMENT IN EVENT OF SER I AL
N o. DUPLICATI ON
REQU I RE M ENT IN EVENT OF SECO N D
OR FURT H ER SE RIAL No.
DUPLICAT ION
VEHICLE SER IAL NUMBER STAMPED

ON THE RIGHT HAND SID E O F FRONT-PANEL UPPER
Figure 0-5
Vehicle Serial Number
TORQUE WRENCH SPECIFICATIONS dicated in Fig . 1- 1. Any attempt to support th e vehi cle at
any but th ese locati ons co ul d resul t in damage to under-
Pro per tig htening of bo lts and nuts is fre qu en tl y th e dif- body attac hments and in stab ility, causing th e vehicle to
ference between a pe rmanen tl y sati sfactorily ope ratin g toppl e.
ve hi cle and an unsati sfactory one. Th e correct tigh ten ing
torqu e can be ob tain ed by usin g a reli able torqu e wrench. WARNING : HOI ST SUPPORTS MUST BE POSITIONED SO
Torqu e wrench spec ificati ons for th e mo re impo rtan t bo lts, AS TO DISTRIBUTE LOAD AND SUPPORT VEHICLE IN A
sc rews and nuts are inc lud ed in il lu strati ons and on STABLE MANN ER.
's pec ifi ca tion' pages at th e rea r of Secti ons whi ch warrant
such inc lusion . In using these speci fications, it must be
remembered that th read tigh tness, di rty thread holes and TOWING OR PUSHING TO START ENGINE
dry thread s will eac h affect th e fin al tig htn ess of a bolt or
nut. If a bolt or nut is lubri cated wh en spec ifi cati ons in -
MANUAL TRANSMISSION
dicate it shoul d be dry, th e fricti on will be red uced, th e work
perform ed by it will be greater and it may be stretched
CAUTION: Towing ca r to start is not recommended due to
beyond its elastici ty lim it. The condi tion would be reve rsed
the possibility of th e disa bled car accelerating in to the
if th e nut or bo lt was not c leaned of foreig n materials and
towing vehicle. However, when a tow start is unavoidable,
was not correc tl y tig htened. General ly, nuts and bolts
turn off all electrical loads such as hea ters, radio, and if
operating in oi l should be oil ed befo re to rquin g and th ose
possib le, lights. Turn on ignition, depress clutch and p lace
operatin g dry shoul d be dry before torqu ing. Grease and
gear shift lever in high gea r. Release th e clutch when your
foreign materi al should be removed fro m th e matin g sur-
speed reaches 15 to 20 km ! h.
faces of all parts, parti c ularly th ose subj ected to torqu e
load s. If th is is not done, alth ough th e initi al torqu ing of the AUTOMATIC TRANSMISSION
supportin g bo lts or nuts may be as spec ifi ed, di ss ipation
of grease and foreign material and move ment betwee n the Do not attempt to start th e engin e by towin g or pu shin g th e
parts due to reduced fri ction may res ul t in loosening of th e ca r. Should th e battery becc me discharged, it will be
bolts or nuts aft er a pe riod of operati on . necessa ry to use an auxili ary ba ttery wi th jumper cables to
start th e engine.
JUMP STARTING WITH AUXILIARY (BOOSTER)

ISOLATION OF BATTERY DURING BATTERY
ELECTRICAL REPAIRS Both booster and disc harged bo'te ry should be treated
carefull y wh en using jumper c abl e~. Foll ow exactl y th e
To eliminate the poss ibility of short circuits , the battery
proced ure outlined below, being careful not to cause
ground cabl e should always be disconnected from th e
sparks:
battery before any electrical repairs are attempted. Wh en
removing and in stalling a battery, th e ground cab le shoul d 1. Set parking brake and place automatic transmi ss ion in
always be discon nected first and recon nected last. Thi s 'PARK ' (neutral fo r manu al tran smi ss ion). Turn off
avo id s th e poss ibility of short ing to groun d wi th th e wrench li ghts, heater and oth er electri cal load s.
whil e working on th e co nn ections of th e pos itive ca bl e. 2. Remove vent caps from both th e booster and th e
disc harged batteri es. Lay a c loth over th e open vent
well s of each battery. These two actions help reduce
th e expl osio n hazard always present in eith er battery
JACKING PRECAUTIONS wh en co nn ectin g 'live ' booster batteri es to 'dead '
batterie s.
Wh en a vehicle is raised on a jack, th e ve hi c le must be
firml y supported on jack stands before any work is at- 3. Attac h one end of one jumper cabl e to the positive
tempted. Se ri ous body injury has far too oft en occurred termin al of th e booster battery (id entifi ed by a red
owing to a ve hi cle wh ich was not suppo rt ed by jac k stands, co lor, " or ' P' on th e battery case, post or clamp) and
slippin g off th e jack. th e oth er end of sam e ca bl e to positive termi nal of
disc harged battery. Do NOT permit cars to touch each
In cases wh ere no jack stands are availabl e - such as wh en other as th is co ul d establi sh a ground co nn ecti on and
changing a fl at tyre on th e road:- co unteract th e benefits of thi s procedure.
a. Appl y handbra ke 4. Attac h one end of th e remaining negative (-) ca ble to
b1 . Manual Transmissio n - Place co ntrol leve r in gear. th e negati ve termin al (bl ack color, '-' or 'N') of th e
b2. Automatic Transm issio n - Pl ace con trol lever in booster battery and th e oth er end to cyl ind er head
' PARK '. earth terminal on six (6) and eight (8) cylind er engin es.
c. Sec urely chock whee ls. (Do not co nn ect di rectl y to nega tive pos t of dead
d. Pos iti on jack as shown on jacki ng instru cti on label on batt ery) - taki ng ca re that clamps from one cable do
in sid e of rear compartment lid . not inad ve rt entl y touch th e clamp on the oth er cab le.
Do not lean over ba ttery wh en making thi s co nn ection.
Care shoul d be taken so that the vehicle is not acc id entally
pushed or bumped off th e jac k. No port ion of th e body Reverse thi s sequ ence exactly when removi ng the j umper
should be all owed beneath th e vehicle at any tim e. cabl e. Re- install vent caps and throw cloth s away as th ey
may co ntain co rros ive acid .
CAUTION: Any p rocedure other than the above could result

in : ( 1) personal injury caused by electrolyte squirting out
VEHICLE HOIST LOCATIONS of th e battery vents. (2) personal injury or property damage
When pos iti onin g a VB Model on a frame type hoist, it is due to ba ttery explosion. (3) damage to the charging
essenti al that th e vehicle be support ed at locati ons in - system of th e booster veh icle or of th e imm obilized vehicle.
VEHICLE TOWING a minimum of 1 Ocm from th e ground , care should be

If proper precautions are not taken, the towi ng of a vehi cle taken to ensure adequate ground c lea rance at th e
ca n be a hazardou s operation . It is preferable under al l oppos ite end of th e ve hi cle.
circ um stances to have th e towing performed by an ex- a. Front Attachment
perienc ed tow truck ope rator with equipment whi c h is The preferred attachment of towin g eq uipm ent
designed for the purpose . and safety c hains is at th e towin g eyes located
Wh en the vehicle is to be towed , the detailed instructions each side of th e front suspen sion cross member.
provid ed by the towing equipment manufacturer should be Ca re must be taken that th e hoo ks and c hain s are
foll owed. Use of a safety c hain which is co mpletely ind e- well clear of the Rac k and Pini on Stee ring Gea r
pendent of th e main towing attachment is essential for tow and the Steering Ti e Rods. A suitabl e protec ti ve
truck ope rat ion and strongly recomm ended when th e c ro ssbar should be pos iti oned ac ross th e ca r
vehicle is towed using a tow rope. When towing with th e under the radi ator support sheet metal to pro tect
rear wheels in co ntac t with the gro und , the Parking Brake lights, bumpers and painted surfaces.
sho ul d be rel eased and th e transmission in neutral. b. Rear Attachment
Veh icles with defective transmissions sho uld not be towed In cases of rear end damage it may be necessary
unl ess the propell er shaft is removed. Vehi cles equipped to lift th e rear end of th e ve hi c le and tow on th e
with automati c transmi ssions must not be towed at speeds front wheels only. In such cases the Stee ring
in excess of 55 km /h or distances in excess of 55km unless Wh eel must be c lamp ed in th e straight ahead
the propell er shaft is removed . Wh en towing with front position , usi ng . a c lamp in g devi ce designed for
wheel s in co ntac t with the ground , th e igni ti on must not be towing service use, suc h as th ose provid ed by
in th e ' Lock' or 'Accessories ' positions, but should be in the towing eq uipm ent manufac turers. Do no t use th e
'Off ' posi ti on unless the engine is runnin g. ve hi cles Steerin g Co lumn Loc k for thi s purpose.
Hooks and safety chain s should be attached to th e
Safety rear towing eye and axle tubes. Pos iti on a suitable
No vehi cle should ever be towed at speeds over 80km / h. wooden cross bar with spacer b loc ks across th e ca r,
Any loose or protruding parts of damaged vehicles such as resting on the underbody sid e memb ers (not th e fu el
tank) to keep the tow ing eq uipm en t c lea r of th e
hoods, doo rs, fend ers, trim etc. should be sec ured prior to
moving th e veh icle. bumpers and painted surfaces.
2. Towi ng by Tow Rope Type Attachment
Points of attachment to the disabled vehicle sho uld be
inspected for damage or dete ri o ration. If an attachment Wh en being towed by tow rope , remember that power
point appears damaged or deterio rated, another at- brake and stee rin g assists are not operative unl ess th e
tachm ent poi nt at a substantial structural me mber shou ld engine is running .
be se lected . The tow rope and safety chain s should be attached to
Never all ow passenge rs to ride in a towed vehicle for any the towing eyes on th e front suspen sion c rossmember
reason. in a position well away from th e rubb er boo ts of th e
Rack and Pinion Steerin g Gear. Thi s is necessa ry to
All state laws co nce rnin g towing mu st be followed . Laws avoid restricting steerin g movements of the lowed
can cover such items as towing speed, warning signs , night vehicle. It may be necessa ry to use a woode n c ross bar
illuminati on, d istan ce between vehicles,etc. und er th e rad iator moun ti ng to protect sheet metal
1. Towing by Tow Truck pan els from damage by th e tow rope .
The vehi cle should be rai sed until the lifted wheels are
LUBRICATION
INDEX
Subj ec t Page Subjec t Pag e
CAPACITIES ...................................................................... 00-07 CLOSED PCV SYSTEM .................................................. 00-09
ENGINE LUBRICATION & SERVICE ............................ 00-07 AIR CLEANER .................................................................. 00-09
S.A.E. VISCOSITY OILS .................................................. 00-07 CRANKCASE VENTILATION FILTER ........................... 00-09
TYPES OF OIL .................................................................. 00-08 AUTO. TRANS. LUBRICATION AND SERVICE ......... 00-10
ENGINE OIL VISCOSITY RECOMMENDATIONS ....... 00-08 RECOMMENDED LUBRICANT ...................................... 00-10
WHEN TO CHANGE CRANKCASE OIL ...................... 00-08 CHECKING TRANSMISSION FLUID LEVEL ............... 00-10
NORMAL CONDITIONS ........................................... 00-08 COLD FLUID LEVEL CHECK ................................. 00-10
SEVERE CONDITIONS ............................................ 00-08 DRAINING & REFILLING ................................................ 00-10
MAINTAINING OIL LEVEL ... ... ........................................ 00-09 LUBE. & MAINT. INTERVALS & DETAILS .................. 00-10
CRANKCASE DILUTION ................................................. 00-09 CONSOLIDATED LUBRICANT RECOM . ...................... 00-13
CAPACITIES
6 Cylinder Engine 8 Cylinder Engine

Crankcase Refill .... ........... ........................... 3.4 litres Crankcase Refill .. ........ ...... .......... ..... ........... ........ .. 4.0 litres
(Less Oil Fi lter) (Less Oil Fil ter)
Oi l Filter ... .... ......... .. ........................ ................. ............. ... .... 8 litre Oil Filter .. .............. ........... ................ .. ... ...... ... ................... .. .8 litre
(Change Only) (Change Only)
Tran s. MC6 4. Speed Torqu emaster ..... .... .......... 1. 76 litres M20 & M21 4 Speed (G MH) .......... ............. ... ......... 2.0 litres
M20 & M21 4 Speed (G MH) ... .......... ... ... ....... ....... . 2.0 litres Trim ati c- Dry ........................... .................. .... .......... .. ...... 8.7 litres
Trimati c- Dry ....................................................... ... .. .. 6.1 litres (In c luding Conve rter)
(In cluding Conve rt er) Refill .... .... ................................................... ................ ...... 2.3 litres
Refil l .... ........... ............... .............. ... .. ..................... 2.3 litres Turbo Hydramati c- Dry .... .. ...................................... . 1 0.4 li tres
Stee ring Gear (In c luding Co nverter)
Manual ........................................................... ......... 190-2 1 Oml. Refill .... .. ........ ................. ....................... ......... .................. 3.7 litres
Power ............................................... ................................... 190ml . Steering Gear
Rear Axle .. .......................... .... .................................. ... ... 1.5 litres Power .... ...................... ..... .. .. ............................................... 190m I.
Rear Axle ................... ................. .. .. ............................... 1.5 litres
NOTE: It is important that th e co rrec t type or grade of oil terval s and Detail s' in thi s Secti on , togeth er with th e rec-
or grease referred to in ' Lubri cati on and Mai ntenan ce In - omm ended frequ ency of appl ica ti on be followed .
ENGINE LUBRICATION & SERVICE
S.A. E. VISCOSITY OILS Th e higher S.A.E. viscos ity numbers, which rep resent
heavi er body oils, are recommended for use durin g warm
S.A.E. viscos ity numbers indi cate onl y th e fluidity or body or hot weather to provide oil econ omy and adequate
of th e oil and do not incl ude oth er properties or quality lubri cation under high ope ratin g temperatures.
factors. The lower numbe rs iden tify oils whi ch fl ow more Oil s are available whi ch are design ed to co mbin e th e easy
readily than oils with th e hi ghe r numbers. starting c haracteristi cs of the lower S.A.E. viscos ity number
Th e lower S.A.E. viscos ity numbers wh ich represent th e with the warm weather operatin g c haracteri sti cs of th e
lig ht body oi ls are reco mm end ed for use during co ld higher S.A.E. viscosity number. Th ese are term ed 'mul ti-
weath er to prov id e easy start ing and instant lubri cation . viscosity ' oils .
TYPES OF OIL Any topping up or repl acem ent of thi s oil before th e first
oil chang e should be mad e usin g 'SE' quality oil con-
In se rvi ce , c rankcase oil s may form sludg e and varni sh and forming to one of the grad es recomme nd ed on th e S.A.E.
und er some co nditi ons, co rros ive ac id s unl ess protected Viscosity / Temperature chart.
against ox idation.
To minimi ze th e formati on of th ese harmful prod ucts and
to ensure th e use of oil best suited for present day op-
erating co nditi ons, automobil e manufacturers have devel -
WHEN TO CHANGE CRANKCASE OIL
oped a sequ ence of tests designed to eva luate th e
resistance of an oi l to th e formation of sludge, varnish and NOTE: Only 'SE' grade oil should be used
aci ds and to eval uate its lubrica ting properti es.
Those oil s whi ch pass these tests are known as 'S E' quality
oil s and are labell ed as such on their co ntainers. Only oils
NORMAL OPERATING COND ITI O NS
certified as 'SE' Quality Oil should be used.
Th e oi l change interval s are based on th e use of oil s whi ch Prevailing Daytime T emperature R egul ar Oil Cha nge Interval s
meet th ese requiremen ts.
NOTE: ABOVE 10°C Every 180 Day s or 10 ,000 km
1. Non-detergent and low quality oil s are specifically not - Whichever occurs fir st.
reco mm ended .
BELOW 10°C Every 30 Day s or 5 ,000 km
2. The use of ' Break-in' oils, 'Tun e- up ' co mpound s,
- Whi chever occurs f irst .
'Fri cti on reducing ' compound s and oth er sup-
pleme ntal additives are not recommended.
Their use will only increase operating costs.
NOTE: Under prolonged dusty driving conditi ons, it is
reco mmended that thi s operation be performed mo re
freq uently.
ENGINE OIL VISCOSITY
RECOMMENDATIONS
The grade of crankcase oil sho uld be selected to give the NORMAL CONDITIONS
best pe rform ance under the climati c and driving co nditions Oils have been greatl y improved, whi ch with engin e im -
in th e territory in which the vehic le is operated . When the provement such as closed c rankcase ventil ating systems,
crankcase is drained and refill ed , th e c rankcase oil should has co nsiderably lengthen ed th e life of good lubricating
be se lected, not on th e basis of th e ex isting temperature at oils. However, to ensure co ntinuat ion of best perform ance ,
the tim e of th e change , but on th e atmospheri c tempe rature low maintenance cost and long engine life, it is necessa ry
range an tici pated for th e period during whi ch th e oi l will be to change the engine oil wh eneve r it beco mes co n-
used . taminated wi th harmful material s. Th e oil drainage interval s
Duri ng warm or hot weath er, an oi l whi ch will provid e listed in the above chart are recomm end ed for norm al
adeq uate lubrication und er high operating temperatures is driving conditions; mainly driving on sea led roads and
under conditions where normal engin e operating tem-
required .
peratures are obtained and maintain ed .
During th e co ld er month s of the year, an oil which will
permit easy sta rting at the lowest atmospheri c temperature SEVERE CONDITIONS
li kely to be enco untered , shou ld be used .
Usually, suburban operato rs or door-to-doo r delivery
Th e S.A.E. Oi l Viscosity / Temperatu re chart ill ustrated vehi cles operate under most severe conditi ons and se ld om
below will se rv e as a guid e in se lecting the appropriate have the oppo rtunity to drive th eir vehi cles in a mann er
grade of oi l for th e ambient driving co nd itions . wh ich will attain and maintain effi cient engine operating
Th e engine oi l pan is initially fill ed in the factory with SAE. temperatures. As a result , sludge form s in th e engin e and
20W20 - 'SE' oil. In areas wh ere th e ambient temperature to avoid thi s, oil mu st be drained at more frequ ent int erval s;
is below 0 degrees C th e initi al fill should be drained and the change frequen cy depending on th e severity of th e
th e oil pan repl eni shed with S.A.E. 1 OW viscos ity oil driving co ndition s. Genera lly, it ca n be sa id th at ve hi c les
...
20W
I 20 - 30 1 20W - 40 I 30 - 40 I 20W - 50
1ow 11 ow _30 11 ow _40 1
A
5W 15W - 10 5W - 20 I
"
- 30°C - 20°C - 10°C o0 c 10°C 20°C 30°C 40°C 50°C
ATM OSPHERI C T EMPERATURE SCALE - DEGREES
GENERAL INFORMATION & LUBRICATION 00-
whi ch cove r trips of 20 km or less are ope rating und er OIL FILTER
seve re co nditi ons . A change period of 30 days or 5,000 km Th e full -fl ow oi l filter with an integral non -return chec k
is suggested for ave rage door-to-door delivery vehi cles or valve filt ers all th e engine oil deli vered by th e oi l pump. It
any ve hi cle ope ratin g und er si milar adverse conditi ons. is therefore important th at th e oil filter be rep laced every
Freq uen t long run s at high speed s with th e resu ltant hi gh 1 0,0 00 km or 6 month s, whi cheve r occ urs first. Under
engine ope ratin g temperature may ox idize the oil , formin g prol onged dusty co nditi ons, it is recomm ended that th e oi l
sludge and va rni sh. Whil e no definite drain interva ls can be filter be replaced more oft en.
recomm ended under th ese condi ti ons, th ey should be
more fr eq uent th an under norm al driving co nditi ons. NOTE: Wh enever the oil filt er is replaced , add 0.8 litre of
the recomm end ed engin e oil to th e oil pan .
MAINTAINING OIL LEVEL CLOSED POSITIVE CRANKCASE

The oil leve l indicator is marked 'full ' and 'add '. Th ese
VENTILATION SYSTEM
no tations have broad arrows poi nting to th e level lin es. Th e All Holden engines in co rp orate a c losed posit ive c ran kcase
oi l level should be maintained between th e two lin es, venti lation system , whi ch utili zes manifold vacu um to draw
nei th er going above the 'full ' lin e nor under th e 'add ' lin e. fume s and co ntamin ating vapours into th e co mbu sti on
Chec k the oil level frequ ently and add oi l when necessa ry . chamber where th ey are burned . Th e closed crankcase
Always be sure the c rankcase is full before starting on a ventilation system has an important fun cti on and should be
long drive. understood and se rvi ced properly. After a pe ri od of op -
It is always adv isa ble to drain th e c rankcase only after th e eration , the ventilator valve may beco me c logged , whi ch
reduces and finall y stops all crankcase ventilation . An
engine has become th oroughly warm ed up and reac hed
normal operatin g temperature. Th e benefit of drainag e is, engine operated without any crankcase ventilati on can be
damaged seriously. It is therefore important th at th e ven-
to a large extent lost, if th e c rankcase is drained when th e
tilator valve be periodically checked at least every
engine is cold, as so me of th e suspended foreign material
20,000 km or 12 months. For in form ation covering rec-
wil l cling to th e sid es of th e oil pan and will not drain out
ommended test proced ure, refer to th e Emiss ion Control
read ily with th e co ld slow movi ng oil.
Systems Service Manual Suppl ement part no. M38066 .
CRANKCASE DILUTION AIR CLEANER

Probably the most serious phase of engine oil deterio rati on Th e air cleaner element should not be cleaned, washed,
oil ed or blown out with compressed ai r. The mil eage in -
is tha t of crankcase diluti on, whi ch is th e thinning of the oil
tervals at whi ch the element requires se rvicin g depend on
by fu el vapour leaki ng by pi stons and ring s and mixing with
ve hi cle operating cond iti ons. Under metropolitan or hi gh-
th e oil and by condensat ion of wa ter on the cyl inder wall s
way co nditi ons, th e element shou ld be rep laced every
and crankcase.
40,000 km . Peri odic checkin g is not req uired unl ess it is
Leakage of fu el or fu el vapo urs into th e oil pan occ ur mostly suspected that th e element is restricted to the extent that
during th e 'warming -up ' period wh en th e fuel is not th o- vehic le performan ce is affected. Under dusty co nditi ons,
roughly vapo ri zed and burned . Water vapour enters th e th e element should be checked for restriction every
crankcase through normal engin e ventilati on and through 10,000 km or more oft en if vehi cle operating condi ti ons
exhaust gas blow-by. Wh en th e engin e is not co mpl etely warrant. Under these co nditi ons th e element shou ld be
wa rm ed up , th ese vapours co nd ense, co mbin e with th e replaced if it is restri cted beyond th e allowabl e limit.
co nd ensed fu el and exhaust gases and form acid co m-
pounds in th e crankcase .
CRANKCASE VENTILATION FILTER
As long as th e gases and internal wall s of the crankcase
are hot enough to keep th e water vapo ur from condens ing , (Located within Air Cleaner)
no ha rm will result. However, wh en th e engin e is run in low In spect at every oi l change and replace if necessary. Wash
tem peratur es , moisture will co llect and un ite with gases in kerosene or replace at least every 40 ,0 00 km; more
formed by comb usti on , resulting in an acid formati on. oft en under dusty co nd itions.
0 -10 GENERAL INFORMATION & LUBRICATION
AUTOMATIC TRANSMISSIONS LUBRICATION & SERVICE
RECOMMENDED LUBRICANT with the engi ne idling and Park range se lected. However,
it is not always possible to adequately warm th e trans-
Trimatic and Tu rbo Hydramati c Automati c Transmiss ions mission fluid in a workshop to acc urately chec k th e level
require a spec ia l lubrican t whi ch has been especially pri or to road test. Should the level have to be chec ked co ld,
formulat ed and tested and is availabl e from all GMH e.g., after transmission replace ment or repair, th e fol lowin g
Deal ers. Fluid bearing th e name ' DEXRON II '' ' toge th er pro cedu re is recommended to allow for th e co nsid erable
with an identification numb er is recommended and sho ul d expansion that will occ ur as the fluid temperature in-
be used . c reases .
1. With the ve hi cle on level gro un d, start the engine and
move th e selector lever through each range to fill th e
transmissi on internal passages.
CHECKING TRANSMISSION FLUID LEVEL
2. With the tran smi ss ion in PARK range and th e engi ne
The transmission fluid level should be chec ked initially on idling .
New Vehicles at 1 ,500 km or 1 month and eve ry 1 0,000 km A. Trimatic Transmission - add suffi cient fluid to
or 6 months th ereafter. It is essential that th e correct fluid bring the level to th e 'DIMPLE' , located app rox-
level is maintained . imately 6 mm below th e 'ADD ONE PINT' mark on
NOTE: It is always good policy to check transmission fluid the level indicator.
level whenever engine oil level is checked. B. Turbo Hydramatic Transmission - add sufficient
The fluid level ind ica tor is housed in th e filler tube located fluid to bring level to 6 mm below th e 'ADD ' mark.
at th e ri ght sid e rear of the engine. The vehicle mu st be on 3. Aft er the tran smission has been th oro ughly warm ed,
a level surface and the tran smi ssion shoul d be at norma l the leve l must be re-checked with th e engin e id ling and
ope rating tempe rature. 'P' se lected . With warm fluid the level should be at th e
NOTE: If the transmission fluid is not at ope rati ng tem- FULL mark on the indi ca tor.
pe rature (ap proximately 80-88 degrees C) th e co rrect
temperature can be rea ched by dri vi ng th e vehi cle 16 km
making frequent start s and stops. DRAINING AND REFILLING
Select 'P' and allow the engine to id le for two minutes. With
th e engine st il l idling in 'P ' remove and wipe th e level in- It is recom mended that th e 'DEXRON II '' ' fluid be c hanged
dicator with a clean non-fluffy rag or pape r, insert, and every 40 ,000 km or 24 month s, whi cheve r occ urs first for
withdraw immediately. If the level is low at normal operating vehic les operatin g und er normal se rvice co nditi ons and
temperature, top up with 'DEXRON II':· · Automatic Tra ns- 20 ,000 km or 12 month s, whichever occ urs first , for
mission Fluid to bring the level to th e Full Mark. Use a c lean vehic les operatin g in heavy duty app lica ti ons (frequent
funnel with a fine gauze filter. Do NOT overfi ll . trai ler towing ,etc.).
Thi s recomm endati on app lies only when ' DEXRON II':''
COLD FLUID LEVEL CHECK Automati c Transmission fluid is used. Oth er flui ds shoul d
The ' FULL ' mark on th e flu id level indi cator, represents the be not used.
co rrect level for a transmission at operating temp erature '' Trade Mark of G M Co rp orati on
LUBRICATION & MAINTENANCE INTERVALS & DETAILS
Th e tim e or distance intervals listed in thi s section are Crankcase Ventilation Filter
in tend ed as a guid e for establi shing reg ular lu brication and
Wash in Kero sene o r replace at least eve ry 40 ,000 km or
maintenan ce pe riods. Sustain ed heavy duty or hi gh speed
12 months, more frequently if veh icle is operated und er
ope ration or ope rati on under adverse co ndition s wil l
dusty co nditi ons. Re fer 'E ngin e Lub ri ca ti on and Se rvice' in
necessitate more frequent servicing.
thi s Section for detail s.
Engine
Air Cleaner Paper Element
Drain whil e hot and refil l with 'SE' quality engin e oi l eve ry
Inspec t eve ry 1 0,000 km and rep lace at least every
10,000 km or 6 month s, whichever occu rs first. Refer
40 ,000 km . Refer 'En gi ne Lub rica ti on and Se rvice' in this
'Engine Lubricati on and Se rvice' in thi s Section for details .
Sec ti on for deta il s.
Engine Oil Filter
Replace eve ry 1 0,000 km or 6 months, whi cheve r occ urs Distributor
first. Refer 'Eng in e Lubri cation and Se rvice ' in this Sec tion The distributor shaft run s in sintered -i ron bus hes whic h
for details. req uire lubrication only during ove rh aul. The shaft sho ul d
be smea red with lithium grease to GMH Speci fi ca ti on Gearshift Control Linkage (Manual and Automatic)
HN1327. A few drops of light engine oil shou ld by added
Apply a light coating of molybdenum disu lphided grease
to the bush lubri cating wi ck through the hole in the side of
to GMH Specificat ion HN1271 to linkage co ntact surfaces
the distributor housing . Every 20,000 km or 12 months th e
every 10,000 km or 6 month s whi chever occ urs first.
ang le of th e co ntact breaker heel should be fi ll ed with heat
Lu bricate gearshift co ntrol mechanism co mpon ents with
resistant grease to GMH Spec ifi cation HN1 369 (th e
HN1271 when disassembl ed du ring overh aul.
quantity to equal two (2) match head s in vo lum e) . Si mul -
taneo usly, th e distributor earn should be spa rin gly Front and Rear Universal Joints
lubri cated with th e same grease. Add two or three drops
of engin e oil eve ry 20,000 km to th e centre felt wick und er Th e unive rsa l joints are lubri cated and perman ently sea led
th e rotor. at tim e of manufacture. Under normal circumstances , no
furth er lubri cation of th e joints is necessa ry. If th e joints are
Starter Motor dismantled during se rvice , repack with lith ium grease to
spec ifi cati on HN 114 7.
Th e start er motor armature is support ed in two oil ab-
so rb ent bushes, whi ch require lubri ca ting on ly during Propeller Shaft Centre Constant Velocity Joint
start er motor ove rhaul. A few drops of li ght engin e oil on
th e dri ve end bea ring and a si milar quantity of light engine The constan t veloci ty joint is lubri cated at assembly. No
oil to th e commutator end bearing is all th e lubrication further lubri cation is necessa ry. If th e joint is dismantled
req uired . during se rvice, repack with molybdenu m disulphide grease
to GMH Specification HN 1583 .
Th e starter motor drive components should be smea red
with chass is grease whenever th e motor is dismantled for Rear Axle (Conventional Differential)
service .
Th e rear ax le requires an E.P. lubricant to ensure sati s-
Generator factory ope rati on. Straight mineral oi l gear lubri cant mu st
not be used. Check level eve ry 1 0,000 km or 6 months,
Re-pack bearing s with high melting point grease to GMH whichever occ urs first. Top up with Hypoid gear oil to GMH
Spec ifi ca ti on HN 114 7 during overhaul. Specification HN 1386 if necessary.
Hypoid gear lubricant to specifica tion HN 1386 is used for
Throttle Control Mechanism
initial fa ctory fill and is recommended for use in se rvice. If
The throttl e co ntrol outer cab le is lined with a resin material unobtainable, EP SAE 90 hypo id gear lubri cant to
and does not require lubri ca ti on. However th e pivot points speci fi cation HN 1187 or HN 1181 may be used as an al-
at th e ca rburettor sho ul d be lubri cated with Zinc Oxide ternative . Seasonal or periodical changes of lubri cant are
grease to GMH Speci fiction HN1225 every 10,000 km or not necessary. The lubricant level should be chec ked with
6 mon ths whi chever occurs first. th e unit cold. At this temperature the lubri cant sho uld be
level with the bottom of th e filler plug hole.
Clutch Pedal
Coat shaft and inside of bushes of cl utch pedal with Rear Axle (Limited Slip Differential)
molybdenum disulphid e grease to GMH Specifi ca ti on Wh enever a limited slip differential assembly is installed to
HN1 27 1. Thi s so uld not be required exce pt when pedal is the rear axle , special lubricant to GM Specifi cation
disassembl ed for oth er reasons . HN 156 1 must be used . Under no circum stan ces must
alternative lubricants be used for eith er refillin g or topp ing
Clutch Control up.
Eve ry 1 0,000 km or 6 month s, lubri cate ca bl e clevi ses with Seasonal or periodi c chang es of lubrican t are not req uired .
molybd enum disulph ide grease to GMH Specifi ca ti on
Check level every 1 0,000 km or 6 month s, whi chever
HN1 271 .
occ urs first . Top up with lubricant to GMH Specification
Whenever th e clutch is dismantled for se rvi ce , th e c lutch HN15 6 1.
throw out fork ball pivot and throw out bea rin g should be
lubri ca ted as outlin ed in 'C lutch and Transmissi ons' Sec - Brake Master Cylinder Reservoirs
tion in thi s Manua l. Check brake fluid level eve ry 1 0,000 km or 6 month s and
Manual Transmissions maintain level 6 mm bel ow lowest edge of each reservoi r.
Use only brake fluid co nformin g to specifi ca ti on
Peri od ic oi l changes for transmi ssion s are not necessa ry GM4 653 M Type 450.
and it is onl y necessary to change th e lubri cant at tim e of
WARNING: BRAKE FLUID ABSORBS MOISTURE QUICKLY
ove rh aul.
AND THIS CAUSES A REDUCTION IN BOILING POINT
Check leve l eve ry 10,000 km or 6 month s, whi chever WHICH CAN AFFECT BRAKE PERFORMANCE. TOPS OF
occ urs first. Top up wi th SAE 80 -90 Multigrad e Viscos ity BRAKE FLUID CONTAINERS SHOULD NEVER BE LEFT
oil to GMH Spec ifi cat ion HN1 046. OFF LONGER THAN ABSOLUTELY NECESSARY.
NOTE: Lubri ca nt level when co ld must be approximately
6 mm below filler hole. Brake Pedal
Coat shaft and in side of bu shes of brake pedal wi th
Automatic Transmissions molybdenum disulphide grease to GMH Specification
Check fluid level on dip -sti ck eve ry 1 0,000 km or HN1271 . Thi s should not be required except when pedal
6 months, whi chever occ urs first, with engin e idling in ' P' is disassembled for oth er rea so ns.
Range and flu id hot. Drain and refi ll every 40,000 km or
24 mon th s, whichever occ urs first, usin g Dexron II ''' Au- Brake Master Cylinder Clevis
tomati c Transmi ss ion flui d. Refer 'Automatic Tran smi ss ions Lubri cate with body hardware grease to GM H Specification
Lubri ca ti on and Se rvi ce' in th is Sec ti on for furth er detail s. HN1225 whenever pedal is disassembled .
Front Suspension Lower Control Arm Ball Joint Do not use ordinary cup or chassis grease as it will melt
Assemblies owing to its low melting point. In mounting the front wheels,
great care must be taken to adjust the bearings properly.
Lubricate with EP Li thiu m grease to GMH Specification
Correct procedure for this operation will be fou nd in
9985038 every 1 0,000 km or 6 months, whichever occurs
first. Section 3 ' Front Suspension ' in this Manual.
NOTE: Grease to specification 9985038 has extreme
pressure properties for effective long life lubrication. If Manual Steering Gear
conventi onal chassis grease not intended for extended
lubrica tion periods is used, the lubrication intervals should After overhaul, fill gear with 190-21 Oml. of EP 140 or
be shortened and should not exceed 3,300 km. SAE 90 gear oil. Refer 'Steering ' Section in thi s Man ual for
details.
Front Suspension Strut Upper Support Bearing
Power Steering Gear
Th e front suspension strut upper support bearing should be
lubri ca ted whenever the support is removed during Service After overhaul, fill mechanical section of gear with 190 mi.
Operations. Before installing the bearing, lubricate with of SAE 40 oil.
5 ml.of wheel bearing grease to GMH Specification
HN1 227 . Power Steering Pump
Check fluid level on dip stick every 1 0,000 km or 6 month
Front Suspension Struts whichever occurs first . Top -up if necessary with Dexron II '''
The wet type front suspension struts are filled with a automatic transmission fluid . Refer 'S teering ' Section in
specified quantity of fluid . Periodi c changes for the fluid is this Manual for filling procedures.
not required; the flu id should only be replaced at the time
of st rut ove rhaul. The approp riate flui ds and capacities Speedometer Cable
are: - The speedometer cable is lubricated at time of assembly
Strut Fluid and should not normally require further lubrication . If th e
cab le requir es lubri ca ti on, first c lean th e cable thoroughly,
Armstrong York .. To GMH Spec. HN1582 P/ N VS14443
then apply Shell Alvania R grease sparingly to the upper
Wylie ............ .......... To GMH Spec. HN1588 PI N VS14444 end of the cable.
NOTE: For strut servicing details, refer ' Front Suspension'
Section in this Manual.
Body Lubrication
Front Wheel Bearings The moving mechanical parts of the body which have metal
Inspect every 20,000 km or 1 2 months whichever occurs to metal contact are lubricated at assemb ly. Operating
first ; repack if necessary. Normal repack intervals are at conditions whether normal or otherwise, determine the
eve ry 40,000 km or 24 month s whichever occurs first. effective life of the lubricant and for this reason, lubri ca ti on
It is necessary to remove the wheel s to lubricate the in service is important. Equally important is th e type of
bearings. The bearing assemblies should be c leaned lubricant to be used.
before repacking with lubricant.Do not pack hub between WARNING : CARELESS OR EXCESSIVE APPLICATION OF
the inner and outer bearing assemblies or the bearing BODY LUBRICANTS CAN RESULT IN STAINING OF PAINT
cove rs (hub caps) as excessive lubrication results in the FINISH OR DAMAGE TO CLOTHING. USE LUB RICANTS
lubri cant working out into the brake mec hani sm. The front SPARINGLY AND REMOVE ACCIDENTAL APPLICATION
wheel bearings are of th e 'tapered' roll er type and sho ul d FROM PAINT FINISH IMMEDIATELY. WHEN LUBRICATING
be packed with special wheel bearing grease to GMH BODY HARDWARE COMPONENTS , USE THE FOLLOWING
Specificati on HN1227 . LUBRICANTS AT THE LOCATIONS NOMINATED.
Part Name Lubricant
Doo r Loc k Strik er Bolts

Door Lock Fork Bolt s ,_____ _ _ Solidoil
Instru ment Compartm ent Lid Lock T o ngue _ _ __J
Engin e Hood Catch
En gi ne Hood Loc k
En gine Hood Hi nge
Doo r Hinge and Hold -Opens
Rea r Compartm ent Lid Hinge
Rea r Compartm ent Li d Loc k Mechan is m
1- - - - Zinc Ox ide Grease t o GMH Specificati on HN1225
Doo r Window Regul ato rs
Doo r Window Gu ides and Cams
Door Loc k Mechan ism
Doo r L ock Rem ot e Control
F rant Seat A dju ster
Recl iner A ssem bly - Fro nt Seat _ _ _ _ __ _ __J
Front Doo r Loc k Cylinders

Ignition and St eeri ng Loc k Cylinder ,_____ __ Powdered Graphi te (appl ied thr ough key ape rture - do not oil)
Rear Compartment Li d Loc k Cylinder
Inst rume nt Panel Compartm ent Lock Cylinder
CONSOLIDATED LUBRICANT RECOMMENDATIONS

Part Name Lubricants
Body. __ .... _ .. _._ . . . . . . . _ ... . _ _ ...... . . . . Zinc Oxide Grease to GMH Specification HN1225
Graph ite Powder
'Solidoi l'
Fro nt Wheel Bearings . . .. _ . . _ .. _ .. . . . . _ . _ .... . . Spec ial Grease, non-soap type to GM H Specification HN1 227
Front Suspension St ruts . .... _ . _ . ... _ .. __ .. ... . . Flu id to GMH Specification :

Armstrong Y ork HN1582. Part No. VS 14443
Wyli e HN1588. Part No. VS1 4444
Fro nt Suspensi on Lower Control A rm Ball Joints
( 1 point on each side ) . .. . . _ . . . __ ... _ .. _ .. _ .. .. . EP Lithium Grease to GMH Specificati on 9985038
Front Su spension Strut Upper Su pport Beari ng . . ... _ . . . Wh eel Beari ng Grease to GMH Specification HN1 227
Rea r A x le A ssemb ly (Con ventional Different ia l ) .... . .. . Hyp oi d Gea r Oil to GMH Speci fi cation HN1 386
Rea r A x le A ssembly (Limited Sl ip Differentia l).... _ ... . Specia l Lubri ca nt t o GMH Specificat ion HN1561
Universal Joints.... _ . . __ ... _ . . . . . . . . . . .... .. . Li t hium Grease to GMH Specifi cati on HN1147
Brake Sh oe A ssemblies _ . . .. _ . . __ ... .... .. . .. .. . Special HT Grease to GMH Specif ica ti on MP6805
Brak e A djusting Screw and Nut . . .. . . .. _ .... _ ... . . Speci al HT Grease to GMH Specifica ti on MP6805
Brak e Hydrauli c Syst em . ..... _ . . _ . _ .. _ .... _ ... . High Boi ling Point Hydraulic Fluid t o Speci fi ca t ion
GM4653-M type 450
Propell er Sh aft Centre Const ant V elocit y Joi nt . . . _ .. __ . Molybdenum Disulphide Grease t o GMH Speci fi cati on
HN1583
Eng ine Oil Pan , L6 Engines, V 8 Engines ... _ . _ _ .... .. . S.A.E.20 'SE' Quality Engine Oil, or equival ent
multigrade oi l
Th rottl e Contro l Pivot Poi nt s. . . .. _ . . . . . . _ .. . . .. . . Zinc Oxide Grease to GMH Specification HN1225
Generato r Beari ngs .. . . ... ... . . _ .. ... _ .... ... . High Melting Point Grease to GMH Specification HN1147
Starter Moto r Bea rings . . . . . . . . . . . . _ .... . . . .... . Light Engine Oil
Dist ributor Cam .... . ... .. ____ _ ... _ . . . .... . _ . Heat Res isting Grease t o GMH Spec ificatio n HN1 369
Di st ributor Shaft Ca m Felt Wi ck .. . _ . . .. . . _ . . . . . . . Light Engin e Oil
Windshield Wiper Pivot Shafts . . . . . . . . .. _ . _ ... . .. . Molybdenum Disulphide Grease to GMH Specifi cation HN1271
CONSOLIDATED LUBRICANT RECOMMENDATIONS (Cont'd.)
Part Name Lubricants
Clutch Th row-Out Bea ring Wheel Beari ng Gre ase t o GMH Specification HN1228
Clutch & Bra ke Pedals .. .. . ..... .. . . . . . . . . . ... . Molybdenum D isulph ide Grease to GMH Specif icati on HN1271
Clu tch Cable Cl evises ...... . . . . . . . . . . . . . ... . . . . Molybdenum D isul phide Grease to GMH Specif ication HN1271
Manu al Transmiss ions ... ... . . . . . . . . . . .... . .. .. . Dual Vis cosity 80/ 90 Oil to GMH Spec ificati on HN1046
Gea rshi ft Con tr ol Linkage ... . .... . ...... .. .. . .. . Molybd enum Disulphide Grease to GMH Speci f ication HN1271
Gearshift Control Mechanism ..... ..... . . .. ... . .. . Molybdenum Disulph ide Grease to GMH Spec ificatio n
HN1271 during overhau l
Automatic Transmissions ... . ... .. . ...... ...... . DEXRON II * Automatic Transmission Fl ui d
Stee ring Gear :
Manual .... .. ...... . . . .. . . . . . . . . . . . . . .... . EP 140 or S.A. E. 90 Oi l
Power (M echanica l) ..... .. . . . . . . . . ... ..... .. . . S.A .E. 40 Oil
(Hydraul ic) . . . . . . . . . . . . . . . . ..... . . . ... .. .. . DEXRON II * Autom atic Tra nsm ission Oil
Speedomet er Cabl e .. . ... . . . . . . . . . . . . . . . ..... . Sh ell Alv ania R I Grease- If requ ired
* Trade Mark of GM Corporation
NOTES
BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS 01-01
SECTION 01
BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS
Subject Page
GENERAL DESCRIPTION ............................................... 01-01
UNDERBODY DIMENSIONS & HOIST LOCATIONS. 01-02
UNDERBODY .................................................................... 01-03
FRONT END ...................................................................... 01-07
REAR COMPARTMENT ................................................... 01-11
DOORS ............................................................................... 01-15
SEATS ................................................................................ 01-29
WINDSHIELD - REAR WINDOW GLASS .................... 01 -43
ROOF .................................................................................. 01 -45
EXTERIOR ORNAMENTATION ...................................... 01 -51
SHEETMETAL ................................................................... 01-55
RADIATOR GRILLE ......................................................... 01 -61
BUMPER BARS ................................................................ 01-63
SPECIAL TOOLS .............................................................. 01-64
GENERAL DESCRIPTION
This section contains details of operations required for The ventilation and heating system featured on 'VB' models
removal , installation , adjustment and maintenance of VB allows fresh or mixed hot and cold air to flow through the
Commodore series body. It also includes detai ls of body vehicle. Air enters the gri lle at the rear of the engine hood
construction and information necessary for co rrect align - and passes through the venti lation and heating system into
ment of underbody. the vehicle . The air is then exhausted from the vehicle
The comp letely restyled 'VB ' Commodore body consists of through a vent grille located at each side roof extension
an integral body frame construction with bolt on front end panel.
sheet metal components. The heating system utilises an air-mix principle where th e
Precoated steel is used extensively for various body panels temperature of the air en tering the passenger compartment
to improve corrosion protection of vulnera ble surfaces of is controlled by the tempe rature lever which regulates the
vo lume of air passing th rough the heater core.
the body.
Reclining bucket type fro nt seats with infinite adjustment
Body and Sheet Metal pane ls such as Engine Hood , Front
Fenders, Trunk Lid , Door Outer Panels, etc., are precoated to the seat back angle are fitted to all models. In addition ,
on the inner face of the metal for imp roved co rrosion a verticle lift seat adj uster is fitted to the driver's seat on
protection . Other body structure members have a complete Commodore 'SL' and 'SLE' Models and is available as an
option for the Co mm odore Model.
precoated finish .
01 -02 BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS
--
-
1-
<t:
&g _J
0
(/) <t:
z "-
I-
0 (f)
~
I
u
0
...J
1-
~
~----------~ ~ 68 ------~ "'c
0
0 :;
0
J: 0
...J
u;
~ ·o
:X:
(/) I ,.... a!!
"'c
z I
I
,....
~
-z
0
( /)
I
I
I
I
:::J
.~ ~
u. Q)
.Q
~
E
I I 0
w II
I
>
:::E "0
I~
,I
0
II .c
c I
:u
"0
c
>
c
::::>
I
0
m
a:
w
r--
c
z
:::)
1
u
·s
Q)
E
~
"'c
~
0
·v;
c
Q)
E
"D
"'
UNDERBODY
INDEX
Su~e~ Page Subject Page
UNDERBODY ALIGNMENT ............................................ 01-03 ROCKER PANEL COVER INSTALLATION ................. 01-05
FLOOR COVERING INSTALLATION ............................ 01-04 CONSOLE INSTALLATION ............................................ 01-06
UNDERBODY ALIGNMENT
•t
Correc und erb ody alignment is essential , as any mis- tram gauge co nsisting of a parall el bar or rod , fitted with
alignment of th e underbody can affect suspension , fitm ent two adjustable trammel s, ca pable of gauging all und erbody
of doors, engi ne hood, or rear compartm ent lid . dimensions speci fied .
Th e underbody should therefore be aligned to within In preparing an und erbody alignm en t c heck, pl ace vehic le
1.6 mm (0.63 in ) of dim ensions spec ified in (Fig. 1- 1). on a level surface with th e weight of th e body supported
Th ese dimensions should be accu rat ely checked with a at wheel locat ion s.
\
0
.....
I
0
FLOOR COVERING INSTALLATION ~
a:J
TRIM-SIDE LOWER 0
c
~-<
CARPET -FRON T FLOOR
en
J:
m
m
-1
s:::
m
-1
l>
SECTIO N A-A
r
JJ
l>
c
SECTION C-C l>
-1
0
JJ
~~.. CARPET - REAR FLOOR
~rt,: ~
G')
-rr-JJ-
PLUG
/1;r=tf:Fl'
- ,.1 m
SECTION E-E Qo
l a:J
c
s:::
//~
"0
m
JJ
a:J
SECTION B-8
A l>
JJ
SECTION F-F J:f! SECTION D-O en
Figure 1-2
Floor covering Insta llatio n
u
6
2
~ll
0
al i=
I u
al LJ.J
Vl
2
0
i= ---- --
u
LJ.J
:I <n
lL
a:f-
LJ.Jz
GO
oa:
a:lL
' _J
OCw
wz
z ><(
8"-
0
~_.
< ~
c:
t; .!!!
..,
z u;
a: ('):c:
w ~ ~
> :;Gl 0
0 (.)
0 .!:!> Qj
_. u. ..,
c:
a.
w
z j
<
a.
CJ
0
a:
a:
w
~
0
0
a:
a:
LJ.J a:
~ <(
u LJ.J
0 a:
a;: _J
a: w
LJ.J z
> <(
0 a_
u
01-06 BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS
z
0
~
...J
c:
0
~. ~.,
~z ,....
~
-
.5
5,..9!
w u:: ~
...J c:
0
0 u
en
z
0
0
/ \
/ .
FRONT END
INDEX
S u~ ec t Pag e Subj ect Page
COMPARTMENT-INSTRUMENT PAN EL ...................... 01-07 PAD-INSTRUMENT LOCATION ..................................... 01-09
REMOVAL .................................................................. 01-07 REMOVAL .................................................................. 01-09
INSTALLATION .......................................................... 01-07 INSTALLATION .......................................................... 01-09
LOCK-INSTRUMENT PANEL, COMPARTMENT ........ 01-07 INSTRUMENT PANEL LOWER ...................................... 01-09
REMOVAL .................................................................. 01-07 REMOVAL .................................................................. 01-09
INSTALLATION .................................. ........................ 01-07 INSTALLATION .......................................................... 01-09
PAD-INSTRUMENT PANEL UPPER ............................. 01-07
REMOVAL .................................................................. 01-07
INSTALLATION .......................................................... 01-09
COMPARTMENT - INSTRUMENT PANEL 6. Prise heater con trol surround pad away from instru -
men t panel. Disconnect hea ter control ro ds and choke
cable.
REMOVAL:
7. Pri se c lock and head lamp switch away from in stru -
1. Pri se hin ge pin from lower right co rn er of in strument
ment panel to gain access to th e instrum ent pad at-
panel compartm ent and remove compartment from tach ing sc rews . Remove sc rews attachin g instrum ent
instrum en t panel as illustrat ed (Fig . 1-5). pad to instrum ent panel.
INSTALLATION : 8. Rem ove sc rews attachin g LH and RH lower pan els.
Reverse removal operati ons. 9. From beneath the instrument pan el remove th e nuts
attaching th e front face of th e instru ment pan el upper
pad to mo unting brackets on the dash panel (3
pl aces) .
LOCK - INSTRUMENT PANEL

COMPARTMENT
REMOVAL:
1. Pri se out retain er cl ip sec urin g In strum ent Pan el
Co mpartm ent Lock to compa rtment l:d as illustrated
(Fig . 1-5).
INSTALLATION :
Reve rse remova l ope rations.
PAD - INSTRUMENT PANEL UPPER
REMOVAL:
1. Pri se upper and lower sid e vents from vent housin g
and remove sc rews attaching vent to instrum ent panel
pad .
2. Remove instrum ent panel compartm ent an d in stru -
ment panel lower trim pa nels.
3. Remove screws attaching upp er and lower secti ons of
stee rin g col umn cover.
4. Remove centre fres h air vent insert s and detach air
du cts from ai r distri buti on housing.
5. Remove sc rew attac hin g inst rum ent cowl and di s-
co nn ect speedo meter ca bl e and electri cal co nn ec tors
from instru ment assembl y. Remove sc rews attac hing
Figure 1-6
instrum ent assembly and ease assembly away from
in strum ent panel. Instrument Panel Pad Installation
0
~
I
INSTRUMENT PANEL COMPARTMENT 0

co
m
0
c
~<
CJ)
:I:
m
m
-1
~
~
r
:xJ
)>
d/ c
)>
INSTRUMENT PANEL
LOWER PART -1
LEFT SIDE . 0
:xJ
r· G')
:xJ
r-
I
'
I r
COMPART'i:';N~ANEL
INSTRUM
r-
m
Qo
m
c
/ ~
"tJ
m
:xJ
m
)>
::tJ
CJ)
Fi gure 1-5
Instrument Panel Compartment
10. The demisi vents are secu red to the instrument panel 7. The centre vent housing is retained to th e instrument
pad by spring clips. To remove vents prise retaining pad by two screws located behind the switches in the
clips away from pad. housing . Prise off each end switch or cover to gain
access to screws.
INSTALLATION:
Reverse removal operat ions. INSTALLATION:
Refer (Fig. 1-6) for installation sequence. Reverse removal operations.
PAD- INSTRUMENT LOCATION INSTRUMENT PANEL LOWER
REMOVAL: REMOVAL:
1. Prise off clips retaining lower trim panels to the un- 1. Prise off clips retaining right and left lower trim panels
derside of the instrument panel. to the underside of instrument panel.
2. Remove screw attaching instrument cowl and dis- 2. Remove screws attaching upper and lower section s of
connect speedo meter cab le and elect ri cal connec tors steering column cover.
from instrum ent assembly. Remove sc rews attachin g 3. Disconnect choke ca bl e and prise heater control
in strum ent assembly and ease assemb ly away from surround pad away from instrument panel. Disconnect
instrum en t panel. heater control rods.
3. Prise heater co ntrol surround pad away from instru- 4. Remove screws attaching the LH and RH lower panels
ment panel. to the instrument panel.
4. Pri se cloc k and head light switch away from in strum ent NOTE: To rem ove the RH lower panel prise the head light
panel to gain access to th e instrument pad attach in g switch away from panel to gain access to th e upper at-
sc rews. taching screw. Disconnect headlight switch wirin g.
5. Detach air ducts from air distribution housing.
6. Remove screws attac hing instrument pad to instrument INSTALLATION :
panel. Reverse removal operations.
SUN VISOR INSTALLATION

WHEN IN STALLING NEW HEADLINING
BRACKET -VISOR SUPPORT PIECE HEADLINING AT MOUNTING
HOLE LOCATIONS BEFORE INSTALLING
VISOR & PIVOT ASSEMBLS .
···;.
' \ _ VISOR & PIVOT ASM
Figure 1-7
Sun Visor Installation
NOTES
- - - - - - - - - - - - - - - - - - - - -- - - - - - -
~ ~ - - - - - - - - - - - - - - - - - -- -
- --- - -- - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - -- - - -- - - - -- -----
REAR COMPARTMENT
INDEX
Subject Page Subject Page
REAR COMPARTMENT LID ........................................... 01-11 LOCK CYLINDER - REAR COMPARTMENT LID ...... 01-12
REMOVAL .................................................................. 01-11 REMOVAL .................................................................. 01-12
INSTALLATION .......................................................... 01-11 INSTALLATION .......................................................... 01 -12
ADJUSTMENT ............................................................ 01-11 LOCK STRIKER- REAR COMPARTMENT LID ......... 01-13
HINGE SPRINGS- REAR COMPARTMENT LID ........ 01-11 REMOVAL .................................................................. 01-13
REMOVAL .................................................................. 01-11 INSTALLATION .......................................................... 01-13
INSTALLATION .......................................................... 01-12 WEATHERSTRIP- REAR COMPARTMENT LID ........ 01-13
LOCK- REAR COMPARTMENT LID ............................ 01-12
REMOVAL .................................................................. 01-12
INSTALLATION .......................................................... 01-12
REAR COMPARTMENT LID
REMOVAL
1. Raise th e rear compa rtm ent (t runk) lid and sc rib e
loca tion of hinge strap on lid inner panel to facilitate
insta ll ati on.
2. Support lid and remove hinge to lid attaching bo lts .
INSTALLATION
Revers e rem oval operations.
ADJUSTMENT
1. Elongated holes in the hing e straps provide forwa rd
and rearwa rd adj ustment of th e lid . Verti ca l adjustmen t
of th e hing e area of the li d ca n be achieved as follows.
a. To raise lid at hing e area, place a shim between
th e lid inner panel and hinge strap at forward
attachi ng bolt locat ions.
b. To lower lid at hing e area, place a shim between
Figure 1-8
th e lid inn er panel and hing e strap at rearward
attaching bolt locati ons .
NOTE: Fol lowing any adjustm en t of th e rear co mpartment
lid it is important that the lid lock striker engages co rrec tly
with th e lid lock. Adjust striker to ensure correct engage-
ment between lock and strike r and to ac hi eve co rrect
alignment between rear co mpartment li d and adjacent
panels .
HINGE SPRINGS- REAR COMPARTMENT

LID
REMOVAL
1. Rai se and support rear compa rtm ent lid .
2. Rem ove ri ght sid e hinge torsion spring by in se rtin g th e
small hooks of Tool KM125 over spring and lever end
of sp ring out of retainin g slot in centre support brac ket
as shown (Fig . 1-8) .
3. Rem ove left side hin ge torsion spring by in se rtin g th e
large hooks of Too l KM1 25 over sprin g and lever end
of spring out of re tain ing slot in cen tre support brac ket
as shown (Fig . 1-9) . Figure 1-9
LOCK CYLINDER - REAR COMPARTMENT

LID
REMOVAL
1. Remove rear compartment lid lock as previously de-
scribed.
2. Using a screw driver prise the lock cylinder retainging
spring away from the lock cylinder housing and re -
move lock cylinder assembly: Refer (Fig . 1-13) .
INSTALLATION
Reverse removal operations.
NOTE: Install lock cylinder retaining spring using
Tool KM206-01 as shown (Fig. 1-14) . Press retainer spring
over lock cylinder housing with tool until spring snaps into
position behind retaining lugs in housing .
Figure 1-10
Figure 1-12
Figure 1-11
4. Disengage outboard ends of torsion springs from hinge

•
•
and remove through access opening in support
bracket. Refer (Fig . 1-1 0) .
INSTALLATION
NOTE: The left side spring 'X' is installed before right side
spring 'Z' as illustrated (Fig . 1 -11) .
LOCK - REAR COMPARTMENT LID Figure 1-13
REMOVAL
Remove screws attaching lock to rear compartment lid
inner panel 'A ' (Fig . 1-12) and remove lock.
INSTALLATION
BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS 0"1-"13
LOCK STRIKER - REAR COMPARTMENT

LID
REMOVAL
1. Scribe location of lock strike r on rear end panel to
facilitate installation .
2. Remove bolt attaching lock striker to rear end panel
and remove striker.
INSTALLATION
Reverse removal ope rati ons.
NOTE : Elongated holes in the lock striker provide adjust-
ment for striker. Fo llowing any adjustment of the rear
co mpartment lid or striker, it is important that th e striker is
pos iti oned to ensure correct engagement with lid lock.
Figure 1-14
Trunk Lid Lock Cylinder Retain ing Spring Installation Tool
KM206-0 1
WEATHERSTRIP- REAR COMPARTMENT
LID
Th e rear co mpartment wea th erstri p is a rubber bulb sec ti on
fitt ed over th e upturn ed flange of the rear compa rtm ent
openi ng. A co ntinuous bead of cau lking compound is
applied between th e lips of the weatherstrip and the flange
to ac hieve a dust and water tight seal.
NOTES
DOORS
INDEX
DOORS - DESCRIPTION ................................................ 0"1-"15 LOCK CYLINDER & KEYS ............................................. 01-20
FRONT & REAR DOOR ASSEMBLY ........................... 01-"16 LOCK CYLINDER ASSEMBLY ...................................... 01-20
REMOVAL .................................................................. 01 -"16 Disassembly ....................................................... 01-20
INSTALLATION .......................................................... 0"1 -"16 Reassembly ........................................................ 0"1-20
ADJUSTMENT ............................................................ 0"1-"16 Disassembly of Lock Cylinder ....................... 0"1-20
DOOR HINGES ................................................................. 01-"16 To Determine Code of Key ............................. 0"1-20
HANDLE - DOOR WINDOW REGULATOR ................. 01-"16 WINDOW GLASS - FRONT DOOR ............................... 0"1-21
REMOVAL .................................................................. 0"1-"16 REMOVAL .................................................................. 01-21
INSTALLATION .......................................................... 0"1-"17 INSTALLATION .......................................................... 0"1 -2"1
DOOR TRIM ....................................................................... 0"1 -"17 WINDOW GLASS - REAR DOOR ................................. 01-22
REMOVAL .................................................................. 0"1 - 17 REMOVAL .................................................................. 01-22
INSTALLATION .......................................................... 0"1 -"1 7 INSTALLATION .......................................................... 01 -22
LOCK ASSEMBLY - FRONT DOOR ............................. 0"1-17 FIXED WINDOW GLASS- REAR DOOR .................... 0"1-23
REMOVAL .................................................................. 0"1-17 REMOVAL .................................................................. 01-23
INSTALLATION .......................................................... 0"1 -"18 INSTALLATION ............... ........................................... 0"1-23
LOCK ASSEMBLY - REAR DOOR ............................... 01 - "18 WINDOW REGULATOR- FRONT DOOR ................... 0"1-24
REMOVAL .................................................................. 0"1 -"18 REMOVAL .................................................................. 0"1-24
INSTALLATION .......................................................... 0"1-"18 INSTALLATION .......................................................... 0"1-24
STRIKER- DOOR LOCK ................................................ 0"1-19 WINDOW REGULATOR - REAR DOOR ...................... 0 "1-24
REMOVAL .................................................................. 0"1-19 REMOVAL .................................................................. 01-24
HANDLES - DOOR OUTSIDE ........................................ 0"1-"19 WEATHERSTRIP - FRONT AND REAR DOOR ......... 0"1-25
REMOVAL .................................................................. 0"1-"19 REMOVAL .................................................................. 0"1-25
INSTALLATION .......................................................... 0"1 -"19 INSTALLATION .......................................................... 0"1-25
REMOTE CONTROL - DOOR LOCK ............................ 0"1-19 BELT WEATHERSTRIP- FRONT & REAR DOOR .... 0"1-25
REMOVAL .................................................................. 01 -"19 REMOVAL .................................................................. 0"1-25
INSTALLATION .......................................................... 0"1 -"19 INSTALLATION .......................................................... 0"1-25
LOCK CYLINDER - FRONT DOOR .............................. 0"1-20 MIRROR- REAR VIEW EXTERNAL ............................. 0"1-26
REMOVAL .................................................................. 0"1-20 REMOVAL .................................................................. 01-26
DESCRIPTION
Front and Rear doors co nsist of inner and outer panels ope rates the rear door glass.
welded togeth er at the outer flan ges and a rolled section Lift bar exte ri or door handles operate th e fork type door
upper fram e whi ch retains th e window glass run channe ls. loc ks in conjunction with the doo r loc k bolt striker.
All doors also incorporate side impact beams. A two key locking system is used with both th e primary key
Door hinge sections are welded to the door facing and and the service key operating the front door loc k cylind ers.
body pillar. A door check and hold open link is a se parate The door weath erstrip incorporates plasti c clips which
attachment between door facing and pillar. retains th e weathe rstrip in holes located around th e outer
The front door sliding glass is operated by a double arm lower edge of the door panel. The top secti on of
scissor type window regu lato r attached to the glass lift weatherstrip is retained in th e rolled sec ti on upper frame.
channel and door inner panel. A cable typ e mechanism
FRONT AND REAR DOOR ASSEMBLY
REMOV AL
1. Drill or punch out rivet attac hin g door check link to
body hinge pil lar.
2. Remove ca ps from hinge pivots . Using Tool
I
No . AU170 drive ou t upper and lower hinge pivot /
sleeves and remove door. Fi g. 1- 15.
INSTALLATION
II
Apply grease to hinge pivot sleeves prior to driving sleeves
into hin ge. Install plactic caps and install new rivet to door
check link.
ADJUSTMENT
Attention should be given to uniform margins and alignment
between door edges and surround ing parts when door
adjustm en ts are made.
Correct alignment of the door can be achieved by th e
following adjustments.
1. Scribe location of st riker bolt on body pill ar and loosen
striker.
2. Align st riker bolt to determin e correct engagement
between door lock and striker and ti ghten strik er
sec urely.
Correct engagement ca n be achieved by vert ica l or
horizontal adj ustm ent of strike r.
Forwa rd or rea rward adj ustm ent of striker can be made by
the addition or deletion of space rs between striker bolt and
body pillar as required .
Figure 1-16
Door Hinge
HANDLE- DOOR WINDOW REGULATOR
REMOVAL
1. Insert Int erior handl e removal tool benea th base of
handle in line with handle as shown. (Fig . 1-17) De-
tai ls of removal too l are shown (Fig. 1- 18).
2. Pu sh too l toward s base of hand le to disengage re-
tainin g sprin g from groove in spindle .
Figure 1-15
DOOR HINGES
Doo r hinge sec ti ons are welded to the door fa cing and
body hinge pillar as illustrated (Fig . 1-16).
The hinge pins are the spli t sleeve type with sea ling plug s
at either end. To remove the hinge pin use Tool No. AU 170 Figure 1-17
to drive pin out of hinge sections as shown. (Fig. 1-15). Door Interior Handle Removal
INSTALLATION
1. Locate retaining spring into handle.
2. Wi th window ful ly raised, press handle onto the re-
gul ator sp line until retainer spring engages with
groove.
Locate the hand le facing forward with the arm of the hand le
poin ting at a 45 deg ree angle above horizontal.
Sheet steel - 2x24x200

I ,;!>
I
">
- · I
<10 -...._;
r - - - -- -
30? I
~~~![-:- -'-~ -~'- - - -r~=~

13.5
Figure 1-20
All dimensions are metric.
Figure 1-18
Door Interior Handle Removal Tool
DOOR TRIM
REMOVAL
1. Operate window to down position.
2. Prise escutcheon from door remote control operating
handle opening in trim pad. (Fig. 1-19)
3. Remove door window regulator handle 'A' as pre-
vious ly described. Remove inside door locking rod
knob 'D' and armrest as shown. (Fig. 1-20).
4. Prise door trim pad away from door inner panel as Figure 1-21
shown. Fig. 1-21 and remove door trim by lifting trim
upwards from door panel.
INSTALLATION
LOCK ASSEMBLY - FRONT DOOR
REMOVAL
1. With the window glass raised , remove window re-
gulator handle, armrest, trim panel and fold back inner
panel seal at the lock area.
2. Remove glass run channel from retainer as shown '1'
(Fig. 1-22). Remove screw attaching lower end of
glass run channel retainer '2'. to door fac ing panel,
disengage upper end of retainer from door frame and
remove retainer.
3. Slide door lock remote control handle assembly for-
ward and disengage from door inner panel. Remove
lock inside locking knob.
4. Disengage door lock actuating linkages as shown.
(Fig. 1-23)
'A' Outside door handle actuating rod
'B' Inside remote control rod
Figure 1-19 'C' Lock cylinder operating rod
01 -18 BODY, SHEETMETAL, RADIATO R GRILLE & BUMPER BARS
5. Remove screws attaching lock to rear face of door and

remove lock through access opening in door panel.
Refer (Fig . 1-24) .
INSTALLATION
Reve rse removal operations. Ensure that actuating rods are
correctly installed to lock levers and the outside door
handle actuating rod is adjusted to effectively operate door
lock. Lubricate frictional surfaces of lock with Zinc Oxide
grease.
Figure 1-24
3. Disengage door lock actuating linkage as shown .

(Fig. 1-25).
'A' Outside doo r hand le actuatin g rod
'B' Inside remote co ntrol rod
·c· Inside locking rod
4. Remove sc rews attac hing lock to rea r face of doo r.
(Fig. 1-26). Pass lock around glass run chann el and
Figure 1-22 remove th rough access openi ng in doo r panel as
shown. (Fig. 1-27).
NOTE: The rear door loc k in co rpo rates a child safety
locking system . By operating a loc king lever located in th e
door facing below the lock the doors cannot be opened
from the inside regardless of the pos iti on of th e insi de
loc king knob. The lock is in th e child safety condition when
th e lever is in th e ' UP' pos ition. When the lever is 'DOWN '
th e door loc k operates normally.
INSTALLATION
Reve rse removal ope rations. Ensure th at ac tuatin g rods are
correctly instal led on lock levers. Lu bricate fri cti onal sur-
faces of lock wi th Zinc Oxide grease.
Figure 1-23
LOCK ASSEMBLY - REAR DOOR
REMOVAL
1. With the window glass raised remove window regulator
handle, arm rest, trim panel and fold back inner pane l
seal at the lock area.
2. Sli de door lock remote control handle assembly for-
ward and disengage from door inner panel. Figure 1-25
BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS 01-1 9
HANDLES - DOOR OUTSIDE - FRONT OR

REAR
REMOVAL
1. With the window glass raised, remove window re-
gulator handle, armrest, trim panel and partly remove
door inner panel seal at the door lock location .
2. Disconnect handle to lock actuating rod '1' (Fig. 1-28)
and remove screws attaching handle to door panel '2'.
NOTE: On rear door it is necessary to remove the door lock

to gain access to door handle attaching screws. Refer lock
assembly - Rear door for removal instructions.
INSTALLATION
Reverse removal operations. On the front door adjust the
outside handle to door lock actuating rod to ensure correct
operation of lock.
Figure 1-26
Figure 1-28
Figure 1-27
REMOTE CONTROL - DOOR LOCK
REMOV AL
STRIKER - DOOR LOCK
1. Prise escutcheon from door remote control opening in
trim pad.
REMOVAL
2. Remove window regulator handle, arm rest and trim
1. Sc rib e position of lock striker bolt on the body lock panel. Partly remove inner panel seal at remote contro l
pill ar to fa cili tate installation. area.
2. Remove striker bolt and spacer using 8 mm Allen Key 3. Slide door lock remote control assembly forward and
in tool rece ss in head of striker bolt. disengage from door inner panel. Disconnect remote
control to door lock operating rod.
INSTALLATION
Rei nstall striker bolt, align to determine correct engage- INSTALLATION
ment between door lock and striker and tighten striker Install and check operation of remote control prior to in -
sec urely. stal lation of inner panel seal and door trim .
1. Adjust striker horizontally or vertically to achieve
co rrect engagement with lock.
2. Forward or rearward adjustment of striker can be
achieved by th e addition or deletion of spacers be-
tween st riker bolt and body pillar as required.
LOCK CYLINDER - FRONT DOOR
REMOVAL
1.
2.
With window glass raised, remove window regulator
handle, armrest, trim panel, and partly remove door
inner panel sea l at the door lock location.
Prise retain ing clip away from lock cylinder as il-
'Gl MADE BY
LANE AMAL.
HARDWARE
AUST.
CO~
BRIGGS & STRATTO~
lustrated. Fig . 1-29 to release lock cylinder. Disengage ~· ~
USA
lock cylind er to lock actuating rod ' 1' and remove lock
cyli nd er through hole in door outer panel.
INSTALLATI ON
Reverse removal operations. Check operation of lock
cylind er prior to installing door trim. 1
2
3
4
5
6
BITTING DEPTH
LOCATIONS
1
2
3
4
5
Figure 1-30
Lock Tumbler Requirement Diagram
Reassembly
Reverse disassembly operations.
Disassembly of Lock Cylinder

1. Using a small thin-bladed screwdriver, ca refully prise
tumbler spring retainer (see Fig. 1-34) from loc k
cylinder, exercising ca uti on so as not to all ow end of
Figure 1-29 screwdriver to penetrate too far under retain er, as thi s
can damage tumbler springs.
2. Lift out tumbler springs.
LOCK CYLINDER AND KEYS 3. Hold lock cylinder with tumbler slots downward s, pull
side bar out with fingers and sharply tap cylind er to
A two key lock system is used on 'VB ' Series. This ccmsists shake tumblers out.
of a primary key (plastic head) that operates the
ignition /steering lock, doors, instrument panel co mpart- To Determine Code of Key
ment and rear com partm ent lid. The se rvice key operates
th e igniti on/stee ring lock and door lo ck only. The keys illustrated in Fig. 1 -30 are to be used to determine
the co rrect tumbler requirements for lock cylind ers.
To maintain th e origi nal key codes for vehicles req uiring
lock cylinder replacemen t, uncoded lock cylind ers and /o r 1. Lay key with point and base of key flush with co r-
component parts consi sting of numbered tumbl ers, spring s respo nding key diagram (see Fig. 1-30).
and spring retainers whi ch can be assembled to suit any 2. Commencing at head end of key, determine and reco rd
key code are available. lowest level (tumbl er depth) that is visible in tumbl er
position No. 1 and subsequent pos itions No. 2 to
The foll ow ing illustrations and instru ct ions show th e
No. 6, inclusive.
method of determining the co rrect tumbler requirements
together with assembly details of Lock Cylind er. 3. Hold cy linder with head of cyl inder away and co m-
mencing at No . 1 tumbler position , in se rt tumb lers into
cylinder slots, using the ord er determined by the key
LOCK CYLINDER ASSEMBLY diagram, ribbed side toward s you and long point down
(see Fig . 1-32).
Disassembly 4. Pu sh tumblers down, then insert a sprin g in th e space
provided in each tumbler slot (see Fig . 1-33).
1. Pri se loc king link from lock cylinder. (see Fig. 1-31)
2. Pri se lock cylind er housing sca lp from cylinder CAUTION: If springs become tangled, do not pull th em
housin g, maintainin g finger pressure on cylinder cap, apart, unscrew them.
whi ch is spring loaded. 5. Reverse lock cylinder so that th e head of th e cylind er
3. Withdraw lock cylin der from cylinder housing. is now towards yo u. In se rt th e spring retainer (see
LOCK I NG CY LI NDER LOCK CYLINDER CY LINDER

LEVER HOUSING CY LI NDER CAP AND HOUSING
SPRINGS SCA LP
l
Figure 1-31
Cylinder Assembly - Door Lock
Figure 1-32 Figure 1-33 Figure 1-34

Lock Cylinder Tumbler Installation
Fig .1- 34) over th e springs with th e two end prong s INSTALLATION
inserted into th e slots in ends of cy linder. Press re - 1. Reve rse removal o perati ons. Slott ed holes in the doo r
tain er down with fingers . inner panel 'B ' and lower attachment of g lass run
6. Insert key from which code was determi ned to a llow c han nel retainer to door facing prov ide adjustment fo r
sid e bar to drop down . If side ba r does not, re move key, co rrect alignment of window glass.
retain er, spring s and tumb lers then reassemb le co r- 2. Ensure tha t, window reg ulator engages co rrectly with
re ctly . wi ndow li ft rai l 'X' and ad j ustment rail 'Y' as shown
NOTE: To remove tumble rs from lock cy linder, p ull the sid e (Fig. 1-36) . Check ope rati on of window glass.
bar o ut with th e fingers and jar th e cylinde r. Th is proced ure
is necessary because after the tumb lers have been pressed
down, th ey a re partial ly re tained in their slots by the side
bar .
7. Remove key and place cylinder in a vice, using leathe r
or wood on ei th er sid e of cylinder to preve nt damage .
8. Stak e tumbl er spring retai ner in p lace by spread in g
cylind er metal ove r each co rner of sp rin g reta in er,
using a ligh t hammer and fin e chisel.
WINDOW GLASS - FRONT DOOR
REMOVAL
1. Rem ove wind ow reg ulator hand le, a rmrest, trim panel
and door inn er panel seal.
2. Remove the sc rews attac hing the window lift er guid e
rail to th e doo r inner pa nel 'B' (F ig. 1-35) and d is-
engage window g lass from the g uide ro ll ers on the
regula to r.
3. Lift wind ow glass upwa rds, tilt at an ang le, and remove
from door through aperture between inner and o uter
panels . Figure 1-35
•• z
Figure 1-37
Figure 1-36
WINDOW GLASS - REAR DOOR
REMOVAL
1. Remove window regulato r handle, arm rest, trim pan el
and door inner panel seal.
2. Remove sc rews attac hin g wind ow c lampin g plates to
actuatin g ca ble 'A' (Fig . 1-37) Lower wind ow to stop .
3. Rem ove window glass run chann el rai l attaching parts

shown 1, 2 and 3 Fig . 1-38. Remove adj ustin g stud
from lower end of window chann el rail.
NOTE: Dimen sio n 'X' - From end of stud to lo ck nut - to
assist installation. Refer (Fig . 1-39). Remove glass run
channel rail from door. Figure 1-38
4. Lift wind ow glass upwards and remove from door as

illustrated . (F ig . 1-40).
INSTALLATION
1. To ensure full travel of door window glass, th e regu lator
cable must be set to the correct position befo re at-
tac hin g window glass to cable.
Wind wind ow operatin g mec hanism up to stop. Locate
window reg ul ator hand le with arm pointing verticall y
downward and wind han dle in an anti-clockwise
di rect ion fo r 2 and a half revo lution s.
2. In stall window glass and attach glass with clamp plates
to actuating ca ble. Locate glass with th e rear c lamp
plate in line with th e lower edge of opening in door
inner panel as illu strated 'A'. (Fig . 1-4 1).
3. Check operation of window glass prior to in stallati on
of inner panel seal and door trim . Figure 1-39
Figure 1-43
Figure 1-40
Figure 1-41
Figure 1-44
FIXED WINDOW GLASS - REAR DOOR
REMOVAL
1. Remove rea r door win dow glass and glass run chann el
rail as prev iously desc rib ed.
2. Slide fixed wind ow glass forward and remove from
door fram e as illustrated . (Fig . 1-4 2).
3. Remove weatherstrip surrounding fi xed glass.
INSTALLATION
Figure 1-42 Reve rse remova l operati ons.
WINDOW REGULATOR - FRONT DOOR
REMOVAL
1. With the window glass raised , rem ove window re-
gul ator handle, armrest, trim pan el, and door inner
pan el seal.
2. Support wind ow in th e raised posi ti on and remov e
sc rews attaching th e window lifter guid e rail to th e door
inner panel '8 '. Fig . 1-43 . Remove win dow regulator
attach in g sc rews 'A' and disengage reg ulator guide
roll ers from wind ow glass .
3. Remove window regul ator through access opening in
door inner panel as illustrated . (Fig . 1-44) .
4. To remove the opt ional power operated wind ow re-
gulator, disconnect the electri cal co nn ecto rs from
motor and remove drive unit from reg ul ator.
INSTALLATION
1. Reverse removal operations. Ensure regulator guide Figure 1-45
rollers engage correctly with window glass and lifter
guid e rail. (F ig. 1-36) .
2. Slotted hol es in the door inner panel '8 ' (Fig. 1-43)
provides adj ustm ent of window lifter guid e rail for
co rrect ali gnm ent of wind ow glass.
3. Ensure that fri cti onal surfaces of wind ow reg ulator
assembly and associated parts are lubri ca ted wi th
Zinc Oxide grease .
4. Check ope ration of window regulat or pri or to sea lin g
attaching screws and installing inn er panel seal and
door trim .
WINDOW REGULATOR - REAR DOOR
REMOVAL
Figure 1-46
1. Remove wind ow regulat or handle, armrest, trim pan el
and door inner panel seal.
2. Remove window glass as prev iously instructed.
3. Loosen ca bl e tension pulley 'A'. (Fig . 1-45) and re-
move cable from pulleys.
2
4. Rem ove sc rews attac hin g the wind ow reg ulator
mechanism to door '8 ' and remove reg ulator through
access open in g in door inner panel.
5. To remove th e opti onal power operat ed wind ow re-
gul ator di sconnec t the electrical co nn ectors from
motor and remove drive unit from reg ul ator.
INSTALLATION
1. Attach wind ow reg ul ator mechanism to doo r and wind
regulator pull ey 'X' into pos iti on shown . (Fig . 1-46)
2. Route ca ble ove r guid e pull eys , beginning with ca bl e
end 'Z' at in sid e of drive pull ey.
Route cable to pulleys in sequen ce shown . (Fig . 1-4 7)
1. Tension pull ey (adjustable)
2. Guid e pu ll ey - Top rea r
3
3. Guide pull ey - Bottom fron t
4. Gui de pull ey - top front Figure 1-47
Figure 1-49
Figure 1-48
3. Wind cable end 'W' onto cable drive pulley. Start at

position '1' and wind cable towards drive teeth in
direction indicated . (Fig. 1-48)
Tighten cable by adjusting tension pulley. Check re-
gulator mechanism for correct operation.
4. Apply a light application of Zinc Oxide grease to
frictional surfaces of window regulator and cable.
5. Ensure that the tension pulley is correctly located . The
notch in the backing plate 'C' must point upwards
when the tension pulley is installed .
6. Install window glass. Check operati on prior to installing
inner panel sea l and door trim .
WEATHERSTRIP - FRONT AND REAR

DOOR
REMOVAL
Figure 1-50
1. Remove weatherstrip from door upper frame and prise
cli ps retaining lower section of weatherstrip away from
door panel. (Fig. 1-49)
INSTALLATION
1. To fit new weatherstrip, start from bottom of door and
locate join approximately 50 mm (2 in .) above the
fourth clip hole from top of door as illustrated .
(F ig . 1-50).
BELT WEATHERSTRIP - FRONT AND REAR

DOOR
REMOVAL
With the window glass down , use a suitable hooked tool as
illustrated Fig . 1-51, to lift the belt weatherstrip and door
moulding assembly away from door panel. Fig . 1-5 1A
INSTALLATION
Figure 1-51
Press moulding down over retaining clips as shown .
(Fig. 1-52). Belt Weatherstrip / Moulding Removal Tool
MIRROR - REAR VIEW EXTERNAL
REMOVAL:
1. Remove door trim pad as previ ously desc rib ed .
2. Remove end cover from mirror remote co ntrol knob .
Spread contro l knob retainer from recess in mirror
ope ratin g shaft and pull knob from shaft.
3. Prise the inner plasti c cover from door frame and
remove sc rews attaching mirror to doo r.
INSTALLATION:
Refer (Fig . 1-53) for detail s of mirror in stal lation .
Figure 1-51A
Figure 1-52
z
0
f=
<{
....)
....)
<{
1-
(f)
~
a: a: a:
w wo
z 1-a:
z lLa:
<t: -
a: (5w:2!
w zO~
> ~s(f)
0 ....)a._ a:
0
Oz~
~;;:o
Z<t:o
OzLL
0Cfl0
a:
w $
z w
z a:
0
0 (f)
<{
a_
a:
w
a: 1-
w ::J
1- q
::J a:
q w
0 >
<{ 0
a_ 0
:2
(f)
<{
a:
0
a:
a:
:2
v.;->
NOTES
SEATS
INDEX
Subject Page Subject Pag e
SEATS- DESCRIPTION .................................................. 01 -29 REAR SEAT ....................................................................... 01-34
FRONT SEAT .................................................................... 01-33 REMOVAL .................................................................. 01-34
REMOVAL .................................................................. 01 -33 INSTALLATION .......................................................... 01-34
INSTALLATION .......................................................... 01 -33 FRONT SEAT CUSHION COVER INSTALLATION .... 01-35
FRONT SEAT ADJUSTER .............................................. 01-33 FRONT SEAT BACK COVER INSTALLATION ........... 01-36
REMOVAL .................................................................. 01 -33 REAR SEAT CUSHION COVER INSTALLATION ...... 01-37
INSTALLATION .......................................................... 01-33 REAR SEAT BACK COVER INSTALLATION ............. 01-38
FRONT SEAT HEAD RESTRAINT ................................ 01-34 FRONT SEAT BELT ......................................................... 01 -39
REMOVAL .................................................................. 01-34 REAR SEAT BELT ........................................................... 01-40
INSTALLATION .......................................................... 01 -34 REAR SEAT BELT- RETRACTABLE .......................... 01 -41
DESCRIPTION
The reclining fron t bucket seat and rear seat co mpri ses a Fig. 1-54 . Th e front seats can also be adjusted forward and
pressed steel frame which accomodates the support rearwa rd by mea ns of ramp type sliding seat adj usters
sp ring s and wires. Th e seat upholstery co nsists of full operated by a co ntrol lever located at th e front of th e seat.
moulded urethane foam pads fitt ed wi th vinyl or clo th /Vinyl Fi g. 1-5 5.
covers. These are retained to th e seat frame by a co m- In additi on an opti onal vertical lift seat adj uster is ava ilabl e
bination of hog rin gs, clips, c lin ch ove r tabs and retaining for th e drivers seat. This provides adjustment to th e seat
wires . height and is cont rolled by a telescopic lever located at th e
All front seats are fitted with a variable reclining mechanism side of the seat as illu strated Fig. 1 -57 . Details of the height
which gives infinite adjustment to the seat back angle. adj uster is shown Fig. 1-56.
0
......
I
w
0
( HEAD R EST RAINT CJ
0
c
~-<
CJ)
. SLEEV E ASM.
:I:
m
& 2.4-3.4 Nm ~
& 20-25 Nm
s::
~
l>
r
STAR KNOB lJ
l>
ATTACH COVER TO HINGE VI EW[8] & \ SCREW
c
WITH CEMENT TO BE APPLIED
TO BOTH CONTACT! NG \ RECLINING S/ BACK ASM. ~
SURFACES 0
f COVER lJ
BUSHING
G")
\Sf~ lJ
r-
r TENSION WASHER
r WASHER
SECT ION A-A r-
m
Qo
CJ
ill S C R E W /.....___ c
s::
,
CIRCLIP "'0
COVER
m
'- MUST BE INSTALLED lJ
. IN THIS POSITION
CJ
'--- CLAJY1P & l>
lJ
CJ)
VIEW[m SECTION B-B
VIEW[g
Figure 1-54
Front Seat Assembly
_J
~
oc
w
0
:S
l:)
w
u
I
1-
_J
0
aJ
_J
I
<(
oc
w
0
~ I
l:)
"·
w
oc
I ~
I l:J
z E
1- z
u lO
w N
z 6N
z
0
u
~
s:w
>
0
......
I
w
& SCREW ~ 1\)
aJ
0
GUI DE RAIL \
c
:<
(/)
:I:
CONNECTING WI RE m
~
! GUIDE R~ s:
ROD ~
I -/.J~/
~
r
VIEW[§]
:c
~ HEIGHT AD JUST ER l>
c
I ~
BUS HI NG
~SCREW ffi
0
:c
C)
:c
ffi -
r-
r-
m
~ QO
~ ~"-,/
aJ
ffi ,,_ COVER -LEVER c
s:
~ - ~d
"'0
ffi m
LEVER ~~
COVER-HEIGHT ADJUSTER
:c
\
SCREW
aJ
)>
\_ CIRCLIP
:c
(/)
/'::..
\ - ili 2A -3A Nm
VI Ew IAI \ _ SPRING
& 20 -25 Nm
Figure 1-56
Front Seat Height Adjuster
FRONT SEAT ADJUSTER
REMOVA L
1. Remove front seat as previo usly describ ed and place
fa ce down on a clean protected surface.
2. Di sconnect seat adjuster operating wire. Refer
Fig. 1-55 .
3. Remove bolts attaching adju ster guid e rail to the sea t
frame and remove adjuster.
INSTALLATION
Reve rse removal operati ons .
Figure 1-57
FRONT SEAT
REMOVAL
1. Slide seat full y forward and remove bolts sec urin g rea r
end of seat adj uster to fl oor. Refer Fig. 1-58.
2. Sl id e sea t rearward and remove bolts sec urin g fron t
end of seat ad ju ster.
3. Remove seat from ve hi c le and pl ace on a clean pro-
tected surface.
INSTALLATION
Reverse removal opera ti ons .
NOTE: Apply seale r around seat adjuster to floor attaching
bolt holes as shown Fig. 1-59 . Tighten attaching bolts to Figure 1-58
20-25 Nm .
&
SCREW
& 20,0-25,0 Nm
A APPLY 5'0 DIA BEAD OF SEALER

AROUND TOP EDGE OF HOLES
I J COVER O UTBOARD MOUNTING
IN FLOOR PAN BEFORE INSTALLATION OF

SEAT ASM
SECT I O N A-A
Figure 1-59
Front Seat Installation
FRONT SEAT HEAD RESTRAINT REAR SEAT

An adjustable head restraint is mounted to the front seat
back with guide sleeves for the head restraint set into the REMOVAL
seat back frame. Refer Fig. 1-54. 1. To remove rear seat cushion, push front edge of seat
cushion downward and rea rwa rd to disengage c ushion
REMOVA L frame from re taining brackets as ill ustrated. Fig. 1-62.
Using a screwdriver prise the spring clips retaining the 2. To remove rear seat back, unclinch retaine rs sec urin g
head restraint adjuster rods in the guide sleeves as il- seat back frame to wheel house as shown Fig. 1-63
lustrated. Fig. 1-60 and remove head restraint. and lift seat back from re taining brackets attached to
the rear compartment front panel.
INSTALLATION
Prior to installing head restraint insert the retainer spring INSTALLATION
beneath head of guide sleeve with the curved side forward Reverse removal operations.
as shown . Fig . 1-61
Figure 1-62
Figure 1-60

BODY, SHEETMETAL, RADIATOR GRILLE & BUMPER BARS 01 -35
(/)
w
u
<1:
...J
0..
'l"
a:c},
W(J
~z
<til:
1--c.:J
wo a:
C!:I w
z
<1:
(/) 1--
w w
u a:
<1:
...J
0..
~ '9
(/) (/)
<1: ~
a:
w a:
> (J
0 0
U I
z
0
i=
<
..J
..J
<
1-
CJ)
z u
a: <(
~
w LL
I
<(
> 0
z
0 <1:
0
u 0..
i=
z (.)
LU
0 (/)
J:
CJ)
::>
u 0..
1-
<
w
...J
u
CJ)
1-
z
0
a:
u.
0
FRONT SEAT BACK COVER INSTALLATION
......
I
w
0)
m
r--
\
~o
- _
<j ?-
A 0
c
l
c
~-<
--~
~ Am1~<> I
\ (/)
:I:
' oc; m
~
VIEW [6] ~
R E TA I N ER ~
A
j
li
i
I
"l ! ) I ) / ) 1"
s::
~
r
······~·~ :c
<~
""' ""''~
)>
c
SECTIO N A- A i L IP-10 PL: ES

~
0
T R IM ASM . ·
:c
G)
:c
~1~]l,--r--
'/
~ r-
r-
._,>. m
.,;,.'<:·::· '
.__,~~
________,
~
ASM -F .S. B.
Qo
"'" ~
COV ER A SM-F .S.B. _ COV
H OG ER
R I N G- PLACES
i ("'*1---
H OG RI NG -4 PLACES :7
I 4
m
~ ~~n
,I
r tj;}.:/ '~'i'
i/
c
11
:
1
""''"
f "'
1 I
J \_) .._)
I ( I
u \ II
I
1 ;1-
\. 'I I
'----t----f-
RETAINER
HOG R I NGS-4 PLACES

s::
"'tt
! \ m
:c
I
I
I m
I HOGR ING -4 PLACES )>
\ CLIP-15 PLACES :c
\v==-~-~~~~~~~~r'
(/)
8VK I 8VX
8VL RETAINER
Figure 1-65
Front Seat Back Cover Installation
REAR SEAT CUSHION COVER INSTALLATION
FR AM E ASM . RETAINER
COV ER ASM.
HOGRINGS - 4 PLA CES
HOGRIN G-41 PLACES EAC H RET AIN ER
m
0
c
~-<
(J)
:I:
m
~
s:::
~
r
RETAINER
J:J
HOGRINGS-5 PLACES )>
L DASM c
~
HOGRING-6 PLACES
RETAINER
"' J:J
"r-
J:J
r-
m
Qo
m
c
.,ms:::
J:J
m
VIEW ~ RETAINER
)>
J:J
(J)
0
Figure 1-66
"""'
I
(.,)
Rear Seat Cushion Cover Installation ......
REAR SEAT BACK COVER INSTALLATION
...
0
w
I
(X)
RETAINER
RETAINER
m
0
-~11
1- m~Jnif~JI ~)·j
HOGRINGS-4 PLACES
EACH RETAINER
c
~-<
Y;r_,_,_
. CJ)
::r:
~.........,.,_ I
COV ER A SM - - - ------._
I m
~- ~~jlt- ~
HOGR ING -77 PLACE S
l· 'j ,: ,'I
. 'ii id >.:___) I ~
. iiJ '\ s:::
~
R ETA I NER ----i---- ;i1/
A c=D I ~\ r
A ,.j I I
:xJ
~ I )>
I
~,: I c
J
---- ·)1 ~
RETA I NER _/ \ ~~ 0
:xJ
HOGRINGS -5 PLACES\
EACH RETAINER \
~
-,------,._______
I ---~
' ~,
- -~
:I
' :/'
G')
:xJ
""
-/... ,~
I r-
·~---- r-
~~ L
i '
B PAD ASM m
Qo
(£
a:J
RETAINER
c
.,m
I
HOG RINGS RIVET
s:::
4I
4 PLACES EACH RETAINER
AR MREST ASM
:xJ
a:J
)>
.(
J.
:xJ
CJ)
A-A SVL SECTION B-8

SECTION ·. ~
sv x ,I
Figure 1-67
Rear Seat Back Cover Installation
FRONT SEAT BELT
SEAT BELT
RETEN TI ON SLID E ~
;---- OJ
' ?!
<r:::::_: ::Jr. 0
0
\_ SEAT BELT TONGUE RETEN TI ON SLIDE
~-<
BR ACKET & SEA T BELT.
RETRA CTOR ASM (I en
1/fl I.· I/ & :I:

m
m
(
~
----
--
: ~I
~---/
-. 0._ ( I
/ / SEAT B E LT BUCKL E ASM SECT ION 8-8
SEAL WITH NON
HARDEN ING SEALER -i
3:
~
' ~--
\ ---------- """'/ ' ~~ -----
----~~------..;---~ - - ~,B
,• ~...... ~
SECTION A-A
-==-· -
c=:--- -:-...::::=-:-
SECTION
SHOWING SEAT BE LT /
D-0
I (( r
JJ
)>
0
WITH SEAT IN FULL FORWARD IN POS ITION .
~
PO SI T ION THE INBOARD PAR T OF THE BELT
IS TO BE INSTALLE D AT AN ANG LE WH ICH
PASSES THROUGH INTERSECT ION OF SEAT
CUSHION & SEAT BACK CON T OU RS .
0
JJ
C)
-JJ
r-
r-
m
Qo
*&~
CA P INNER
OJ
SECTION C-C c
.- ~ s::
""C
BELTS MUST BE INSTALLED IN
SETS ACCORD IN G TO SUPPLIER m
IDE NTIFICATION (PAR T No SU FF IX
SEAL WITH
JJ
& COLOUR E D ST ICKER I
NON HARDENING COV ER OUTER OJ
SEALER
)>
& 53-71 Nm JJ
en
0
Figure 1-67 A """'
w
I
Front Seat Belt (0

0
......
REAR SEAT BELT I
~
0
A
m
--~\ \ ~ ----------- --
.. 0
c
~~----
ill ~-<
'A-----.. ------------ (/)
:I:
* LAP & SHOU LDER
m
BELT ASM
m
d
BELT BUCKLE ASM
/' -t
c:: / D s::
.----; · ;;;. r~:~-_~ I
D :'
~
'. c ~ '~\.f._.__-------.. ~
~
~···~ ~ "'
)>
\ @ ----- r
~.
::0
~;/''CENTRIENSTALLED
CENTRE LAP -. ...___________! LAP BUCKLE )>
BELT ASM SECTION A-A c
·- T O BE \ )>
~ -t
ON L.H. SIDE
69 STYL ES ---------- -
0
::0
-----------
C)
-rr--
::0
r& CEN TRE LAP BUCKLE

T O BE INSTALLED IN
UP PER POSITI ON ----.. :
I I/). m
Qo
CENTRE LAP BELT TO BE
INSTALLED IN LOWE R
POSITION · - - - SEAL WITH
NON HAR DEN ING SEA LE R ill I ,~
SEAL W ITH NON -
~ARDENING SEAL ER
s::
"'1J
& m
12032 3
::0
SECTION C-C SLEEVE m
)>
SECTIO N B-8 SECTION D-D ::0
* BELTS M UST BE INS TALLED IN MATCHED SE T S (/)
AC CORDING TO SU PPLIE R INDENTIFICATION .
(PART No. SUF FI X & CO LOURED STICKER ) & 53 -7 1 Nm
Figure 1-678
Rear Seat Belt
REAR SEAT BELT RETRACTABLE
,--ffi
SEA T BELT ""
SASH GUID E
RETENTION SLID E
\
<...
___---/ CJ
0
c
------- ;<
en
:I:
m
m
1 ~I
SECTION A-A
-t
s::
m
-t
)>
r
~-
L c ENT R E LAP BUCKLE ::c
BELT
BUCKLE ASM TO BE I NSTALLED 1:\ -....._______ I )>
ON L . H . SIDE L.!.::, c
5>
-t
,----- - & 0
::c
G')
- NON HARDENING ::c
SEALER SEAL W ITH r-
NON HARDENING r-
C-C
CENTRE LAP BELT TO BE
INSTAL LED IN UPPER POS ITION
_// SEALER m
Qo
CJ
SE CT ION
c
SECTION D-D 3:
"::cm
* BELTS MUST BE IN STALLED IN MATCHED
SETS ACCORDING TO SUPPLIER
IDENTIFACTION (PART No. SU FF IX SECTION B-8
& COLOUR ED STICK ER ).
CJ
)>
::c
& 53 -71 Nm en
0
...J.
Figure 1-67C I
~
Rear Seat Belt Retractable ...J.
- .
NOTES
WINDSHIELD & REAR WINDOW GLASS

INDEX
Subject Pag e Subj ect Page
WINDSHIELD GLASS ...................................................... 01 -43 REAR WINDOW ................................................................ 01-44
REMOVAL .................................................................. 01-43
BODY WINDSHIELD OPENING CHECK .............. 01-43
INSTALLATION .......................................................... 01-43
WINDSHIELD GLASS
Ti nted laminated wind shi eld glass is fitted to all VB mode ls.
REMOVAL 2 1N (50 8 MM ) LON G PI ECES OF OLD

WEATHER STR IP
1. Remove wind shield wiper arms and blad es. (Refer
Section 12).
2. Remove rear vision mi rror.
3. Remove inse rt escutc heo ns and in sert sec ti on from
win dshield rubbe r chann el.
* APPLY SEA L ER BETWE EN
4. To remove the windshi eld glass and rubbe r chann el, CHAN N EL AND G LASS AND BETW EEN
app ly hand press ure from in side th e vehi c le and press CHANN EL AND BO D Y ARO UND ENTI RE
th e glass outwards. As a safety precaution against th e WI NDOW OPENIN G AFTER INSTA L L ATI ON
glass breaki ng, leather or thick clo th gloves shoul d be T O ENSUR E A WA TERTI GHT SE A L.
worn . If moderate pushing with th e hand s fai ls to free
th e glass and glazi ng channel a steady foo t pressure
may be applied , usi ng a pad of fel t beneath the feet to
distrib ute the pressure evenly and protect glass.
5. Clean old sealer from around body opening flange and
weathe rstrip cha nnel. SECTION A -A
Figure 1·68
BODY WINDSHIELD OPENING CHECK Windshield Check and Installation
1. Th oroughly chec k body openin g wind shield flang e for
any irreg ulari ties before in stal lati on of replace ment
wind shi eld .
2. To utilize th e wind shi eld glass as a temp late for
chec king th e ali gnment of th e wind shi eld openin g, c ut
four rubb er space rs, (50 mm ) 2 in. from a spare retain er channel all aro und , leaving end s protru ding
weatherstri p. central ly at upper edge as shown in Secti on A-A,
Fig. 1-68 . Tape ends to inside th e glass.
3. Place th e four spacers on th e openin g fl ange at
locations shown in Fi g. 1-6 8 and with th e aid of an 3. With th e aid of an ass istant, ca refu ll y place win dshi eld
assistan t, positio n th e glass centrally in th e opening . assem bly cen trally in wind shield opening, using
centreline marking s on glass and body.
NOTE: Havi ng posi ti oned the glass on the rubber space rs,
examine th e general relationship of glass to openin g flan ge. 4. Whi le pressin g firm ly from outsid e th e body, have th e
ass istant in side the body , slowly pull th e co rd from the
CAUTION: Care should be taken to ensure that glass does
centre posi tion toward each upper co rn er of wi nd-
no t strike th e winds hield opening. Chipped edges can lead shie ld to seat lip of glass retain er chann el over top of
to subsequent breakage of glass. opening flan ge, then pul l cord down both sides and
toward bottom centre of wind shield.
4. Chec k and if necessa ry , re-form th e body fl ange to
prod uce a uniform flange to glass contour. 5. Apply sea ler between glass and outer wall of rub ber
chann el, and between channel and body compl etely
5. Hav ing cor rec ted any irreg ul ari ties and with the glass around perimeter of glass. Fig . 1-6 8
still in pos ition, ma rk cen tre line of glass and body so
th at glass can be acc urately located in th e openi ng. 6. Ensure that the outer sea ling lip of the glass retai ner
c hannel is sealing correctl y on th e body, th en clean
away any surplus sealing compound from glass and
INSTALLATION chann el.
1. Assemb le glass re tainer channel on glass wi th its 7. In stall windshield insert and esc utcheon, usi ng a too l
sec uring lip towards concave side of glass. as ill ustra ted Fig . 1-69 to li ft lip of rubber channel over
2. Insert a strong cord inside body flange cavi ty of glass in sert.
8. With an assistant c hecking inside body and using a

moderate spray , water test aro un d edges of wind - .._ Steel SAE 101 0- 6%x 130
shield , working progressively from bottom of wind - §
shield to top . Where leaks are enco untered , app ly
additional seal er.
9. Install wind shi eld wiper arms so that with wiper motor
in parked positi on, the RH blade is 28 plus and minus
5 mm and th e LH blade is 41 plus and minus 5 mm
above top ed ge of glass retainer channel at bottom of
wind shi eld .
REAR WINDOW
ALL DIMENSIONS ARE METR IC.
Rear window removal and installation procedu res are
similar to those for windshield (ref er preceding instruct -
ions) .
NOTE: Prior to rear wind ow removal , disconnect heated Figure 1-69
rear window glass wiring (violet lead) . Windshield and Rear Window Insert Removal / Installation Tool
ROOF
INDEX
Subj ect Pag e Subject Page
HEADLINING ..................................................................... 01-45 VINYL ROOF COVER ...................................................... 01-46
DESCRIPTION ............................................................ 01-45 DESCRIPTION ............................................................ 01-46
REMOVAL .................................................................. 01-45 REMOVAL .................................................................. 01 -46
HEADLINING NOTE: Li sting wires are identified by co loured paint at one

end of each wire , Fi g. 1-7 0 illustrates listing wire co lou r
code and part numbers.
DESCRIPTION
2. App ly a (50 mm ) 2 in . wid e band of trim cement
Th e roof head linin g, which foll ows th e co ntour of th e roo f, around entire outer edg e of head linin g.
is suppo rt ed in its c urved shape by transverse listing wires
3. App ly trim ceme nt to surfaces of body to which outer
located in holes spaced at reg ul ar intervals along the roo f
edges of headlining are to be attached .
side rail s, as illu strated in Fi g. 1-70.
4. In stall ends of No. 2 li stin g wire into holes in roof side
The li sting wi res are in se rt ed through a se ri es of stitched rail s (see Section C-C Fig. 1-70).
listing poc kets, eac h co in cidin g with stitch lin es vis ibl e
across th e head lining . NOTE: If a new headlining is be in g install ed, it may be
necessary to trim li sting pockets away from listing wires
Th e edges of th e head lining are cemented to th e metal suffi ciently to avoid 'bun chin g up ' of headlining material
flan ge at windshi eld and rea r wind ow openings , rea r parcel where listing wires enter roof side rai ls.
shelf sides , roof sid e rai ls and door openin gs.
5. Pi erce No. 2 listing pocket in line with roof support
A fini shing lace surroundin g the door openings assists in clinch over tabs. Locate tabs through pockets , under
retaining and protecting th e headlining edges against listing wire and bend tabs over, securing No. 2 listing
damage. wire to roof support (see Section D-D Fig . 1
NOTE: Clean hands are essential when working on the 6. Install ends of Nos. 1 ,3 and 4 listing wires into holes
body in terior trim. in roof side rails so that the wires fit firmly against the
roof panel. (see Section C-C Fig. 1-70) .
REMOVAL 7. Using Paul -Call No. 27-2 clamps or equivalent, tem-
1. Disco nn ec t battery ground ca ble and remove dome porarily attach headlining to centre of wind shield and
lamp . rear wind ow flanges .
2. Remove interior rear vision mirror and sun viso rs (see 8. Check that headlining listing pocket stitch seams are
Fi g. 1-7) . evenly ali gned with th e roof side rai ls and if necessary,
3. Remove assist handl e and coat hook assemb lies (see repositi on.
Fi gs. 1-70, 1-7 1). 9. With head lining co rrectl y positioned (see Sections A-A
4. Remove re ar seat cushion, seat back and rea r parcel and G-G, Fi g. 1-70) firmly pull down and c lamp front
shelf trim. Remove rea r sea t belt at upper attachment. and rear end s of headlining to body openings from
5. Remove wind shield and rear wind ow (refe r wind sh ield centre , outward s.
and rear wind ow removal instructions). 1 0. Firmly pull down and clamp headlining around back
6. Detach fini shin g lace from around upper part of door window openin g and attach headlining to rear parcel
aperture fl anges. shelf (see Section H-H , Fig. 1-70) .
7. Ease edges of headlining away from adhesive sec urin g 11 . Firmly pull down and clamp sides of headlining around
he?d linin g to body. door openings, nicking headlining around radii to
8. Disengage end s of Nos. 1, 4 and 3 listing wires from achieve a wrinkle free installation. Turn back head-
holes in roof side rails . (see Fig . 1-70). lining material at front and cen tre pillar on itself for
(12 mm ) .5 in. (see Section B-B and E-E, Fig . 1-70).
9. Ease back tabs sec uring No. 2 li sting wire to front of
roof support (see sect ion D-D, Fig. 1-70). 12. Remove c lamps and smooth out any wrinkles in th e
headl in ing (it may be necessary to disengage edge of
1 0. Di sengate ends of No. 2 li stin g wire from roof sid e rail s, headlin ing to ac hi eve this) .
remove head linin g assembl y from ve hi cle and place
fa ce down on a clean protected surface. 13. Trim off any excess headlining and clean off excess
cement.
11 . Clea n off or smooth down any hardened ce ment from
surfaces to which the edge of th e head lin ing is to be 14. In sta ll finishing lace around door openings.
attac hed. 15. Install windshield and rear wind ow.
16. Install rear parcel shel f, rear seat back and c ushion
INSTALLATION · assemblies.
1. If th e li stin g wires have been removed from th e 17. In stall sun viso rs and interior rear view mirror (on new
head lining or if a new headlining is to be installed , headlinin gs it will be necessary to pierce the head -
instal l listing wires in th eir co rrect listing poc ket. lin ing at these locations: see Fig . 1-7).
18. Install seat belt , assist handle and coat hook assem- marks which result are extremely difficult to remove.
blies (see Figs. 1-70, 1-7 1). 4. Position cover so that both co ver and roof panel centre
19. Reconnect wiring to dome lamp and install dome lamp lines co incide, allowing sufficient material ove rh ang to
to roof. permit clamping of cove r to windshield and rear
wind ow opening flange s. Ensure that seams are co r-
VINYL ROOF COVER rectly aligned , as illustrated in Fig . 1-72
5. Smoo th out and sec ure front and rear ends of cove r
DESCRIPTION to upper flanges of windshie ld and rear window op-
en.ings, usi ng 24 c rocod il e clamps (Paul Cal l No. 27 - 2
The vinyl roof cover is attached to the roof panel and drip or equivalent) evenly spaced across flange s.
gutters with Trim Adhesive such as 3M Nitril e vinyl ad-
6. Release clam ps sec uring RH side of cove r to wind-
hesive or equival en t as illustrated, Fig . 1-72. The vinyl roof
shield and rear window opening and carefully fold
cove r is opti ona l on all sedan models.
cove r back along cen tre line, exposing inner surfaces
(ensure that no pressu re is inadvertently brought to
REMOVAL
bear on the fold) .
1. Protect painted surfaces by masking over all doors,
7. Apply an (200 mm) 8 in . wi de strip of cemen t to roof
rear end of engine hood and front fenders , instrument
panel , adjacent to cen tre line. Ca refull y apply cove r
panel and lower part of rear wind ow openin g.
and smooth it out over area to which adhesive has
2. Rem ove windsh ield and rear window assemblies (refer been applied .
Wind shi eld and Rear Window rem oval in struction s) .
8. Apply adhesive over rema in ing RH side area of roof
3. Remove roof side reveal drip gutter and rear quarter panel, except around windshield and rea r wind ow
belt moulding s and moulding retainer c lips (refer ex- openings . Smooth out cover toward drip gutters and
terior Ornamentation removal instructions). replace clamps . Repeat this operati on on LH side of
NOTE: The application of heat to the cover prior to its roof panel.
rem oval will soften the adhesive and assist in remova l of IMPORTANT: The application of Trim Adh esi ve shou ld be
cover from roof pan el. as thin as possible as an excess amo unt of ad hesive ca n
result in trapped so lvents (blisters) or 'hi ghligh ts' (ad hes ive
CAUTION: Heat may be applied by lamps held no closer build up) between roof pan el and co ver.
than (450 mm) 18 in. from co ver until cover is warm.
Lamps held too close or cover heated over 90 degrees C NOTE: To facilitate installation of cove r along seams and
can cause cover to lose it grain, blister or become shiny. drip gutter, take a piece of plactic sheetin g approximately
(200 mm ) 8 in. x (50 mm ) 2 in. x (3 mm ) 1/ 8 in . and roun d
4. Loosen edges of roof cover at windshield , roof sid e off all co rners to a (6 mm ) .25 in . radius . Use thi s plastic
rail s, rear wind ow and rear quarter area prior to tool to rub al ong cove r at seams and in drip gutters to
carefull y easing off cover from roof panel. ensure good adhesion of cove r.
INSTALLATION 9. Remove clamps sec uring front end of cover to wind-
shi eld opening flange .
IMPORTANT: Pri or to th e installation of cover, ensure that
the surface to whi ch cover is to be attached is smooth and 1 0. Apply adh esive to upper windshield fl ange and down
free from old harden ed adhesive which may highlight windshield pillars. Install cove r to these areas , th en
through after the new co ver is installed . An Xylol so lvent replace clamps .
such as 3M Adhesive Cleaner or equivalent should be used 11. Remove clamps sec uring rear end of cover to top and
to remove old cement. sides of rear window flang es.
12. Trim lowe r section of cover flush with lower edge of
CAUTION: Exercise care to avoid excessive softening of moulding (Section A-A Vi ew A Fig . 1-72) .
roof panel acrylic sealer. Follow manufacturer's directions 13. Apply adhesive al ong top and down sid es of rea r
wh en using adhesive cleaner. window opening flanges and over rea r quarter outer
NOTE: To facilitate the fitting of the roof cover and the panel upper (see View A Fig. 1-72) . Install cove r to
rem oval of wrinkles, etc. install the cover at room tem - these areas , th en replace clamps.
perature (app roxi mately 23 degrees C) . 14 . Apply adhesi ve along ro of drip gutters.
1. Determin e and mark with cha lk cent re lin e of roof at 15. Smooth out any air bubbles or wrinkl es in cove r and
windshield and rea r window openings. pulling sides of cove r tau t, use th e special plasti c tool
2. Place cover, grain downwards on roof pan el and to work cover into the drip gutter (see Sec ti on B-B,
working from side to si de, apply an even coat of Trim Fig . 1-72).
Adh esive to the comp lete inner surface of the cove r. 16. Remove clamps and install drip gutter roof sid e revea l
All ow cover to comp lete ly dry, whi ch usually takes moulding , rear quarter be lt moulding and front body
between 15 to 20 minutes, depending on atm ospheri c pillar moulding .
conditions . 17. Install windshield and rear wind ow (refer Wind shield
NOTE: A mohair roller or equivalent may be used to apply and Rear Window In stal lati on instructions) .
the adhesive sho ul d spray equipment be unavai lab le. NOTE: Normally, minor c reases or fold marks will gradua ll y
3. Wh en cover is comp letely dry, reverse cove r, grain disappear after cover has been in se rvi ce .
upward s. Loosely fold cover lengthwise, back on itse lf IMPORTANT: The cover should be all owed to dry for ap-
to determine centre line of cover, then mark front and proximately 4 hours after installati on . If th e cover is sub-
rear locations with chalk. Replace cover ove r roof, jected to extreme direct sunlight or heat immediately aft er
grain upward s. installation , bli stering may occ ur due to trapped solve nts.
CAUTION: It is essential that when folding th e co ver, no Do not apply excess ive press ure when wiping cove r as
pressure is brought to bear on the actual fold, as th e crease damage to grain of cove r may occ ur.
~ 90043416 (GR EE N )
9004 37 64 (Y ELLOW)
/ / H EA DL IN ING T O BE
~ 9287889 (PL A IN) // T URNE D UNDER -, m
\\
\•, ~
L
12 0 0
cJ~ i- c
y
;<
CJ)
TR I M-FRONT ~ SECTION A-A SEC T ION B-B :I:
BODY PILLAR
8V L X.
m
~
COVER-CENTRE
PI LLAR UPPER
r GROMME T (6 PLACES ) s:
~
..------ FI NIS H LACE
;'-~-~
~~
' r
)>
f
-=,
. JJ
)>
jJ ~ . c
= ---- =-=?"
~
'?;:::::c= . -
~~
0 0
\~
~ TRIM -R EAR QUARTER SI D E L OWER
SECT ION C-C v 0
JJ
~ ~1
~
C)
HEADLININGTOBE
TURNED UNDER j_ JJ
~
12.0 ' r-
r-
~
1 \
~ SECTIO N D-D m
t~ E-E Ro
~ II -" SECTION F-F SECTION
t~~
~ () m
"' c
3:
VIE w lAI SECTION G-G '-- ~ . ATTACH
TRIM WITH ADHESIVE APPLIED
OVER ENTIRE CONTACTING SURFACES ""0
m
() ATTACH HEADLINING TO THE OUTSIDE OF FRONT & REAR WINDOW OPE NING JJ
FLANGES & DOOR OPENING FLANGES WITH TRIM ADHESIVE . A PPL Y ADHESIVE =
FOR ENTIRE LE NGTH OF HEADLINING EXCEPT AROUND TOP OF FRO NT BODY
"-
m
PILLAR REFER SECTION B-B. DIM. IN mm )>
JJ
SECTION H-H CJ)
0
-4
I
Figure 1-70 .t;.
Headlining Installation
......,
0
......
I
LOCA TE N UTS I N SID E I NNER PA N EL , ~
AN D PIER C E H EA DLI NING . CXI
m
0
c
;<
en
:I:
m
~
s:::
~
', ~r_))
)>
r
AFTER IN STALLATION
Jl
)>
OF H A ND G RIPS SN A P .. ~ VIEwlAI A SSI ST HAND L E
CAP OV ER SCREWS AS c
~
SHOWN LEFT SIDE O NL Y
SECTION A-A 0
Jl
C)
L OCATE NUTS IN SIDE INNE R PANEL ,
AND PIERCE HEADLINING . -Jl
r-
r-
/
r
NUT T O BE INSTA LLED
PRI O R T O HEADLINING
IN ST A LL A TION
m
Qo
~5~
m
c
,m
s:::
Jl
m
SECTION 8-8 )>
Jl
en
VIEW [!;ij
RI G HT & LE FT SI DE
Figure 1-71
Assist Handle Installation
Cl
0
0
_-<
ROOF PANEL COVER ASM. en
TO BE COVER ED B Y MO ULDING :I:
m
~
3:
~
l>
ROOF PA NEL
r
PUNCH H~~E (iNPLA C ES R / L) ..&:==\
( COV ER A . ~ JJ
~
l>
0
~
.. )\
(
~~\ LI ~EMOULD
CU T ERED
COV OFF B TOBE I NG
0
JJ
C)
C-C
SECTION A-A SECTION
SECTION E-E
-rJJ-
1
't
ROOF PANEL COVER ASM. m
TO BE COVERED BY
Qo
L\
MOUL DING .
Cl
c:
B-B SECTION D-D
APPLY A 50,0 BAND OF
ADHESIVE ON UNDER SIDE OF SEAM
s::
SECTION "'1J
FOR ENTIRE LENGTH . m
ATTACH COVER T O BOD Y WITH ADHESIVE APPLIED SECTI ON F-F JJ
TO BOTH CONTACTING SURFACES OVER ENTIRE AREA .
Cl
l>
JJ
en
0
......
I
Figure 1-72
~
External Roof Cover Installation (0
NOTES
,
I
EXTERIOR ORNAMENTATION
INDEX
EXTERIOR ORNAMENTATION- DESCRIPTION ....... 01-51 MOULDINGS- DRIP GUTTER ....................................... 01-53
ADHESIVE BACKED NAMEPLATE .............................. 01-53 REMOVAL .................................................................. 01-53
PROTECTIVE STRIPS - BODY SIDE ........................... 01-53 INSTALLATION .......................................................... 01-53
REMOVAL .................................................................. 01-53 WINDSHIELD AND BACK WINDOW INSERTS .......... 01-54
INSTALLATION .......................................................... 01-53 REMOVAL .................................................................. 01-54
INSTALLATION .......................................................... 01-54
DESCRIPTION
Exterior emblems and mouldings are secured to the body be protected against damag e by th e use of maski ng tape
and sheetmetal with various nylon retaining clips, screws, applied adjacent to the part to be removed . Where screws
and tubular loc k type clips as shown Figs. 1-73 and 1-7 4. or tubular lock type clips are used to sec ure nam eplates
The model name plates and engine size badges have an or moulding retainers to panel s, it is essential that a sealing
adh es ive foam backing which bonds the part to the panel. compound be applied around nameplate or moulding holes
prior to installation of screws or clips to effect a watertight
Exterior ornamentation is generally applied over paint seal.
finish surfaces , therefore , it is important that the paint finish
0
......
I
U1
N
m
0
EMBLEM-
:J RIP MOU LING-
FRONT PILLAR -,
MO UL DING -R A IN DEFLECTOR c
~-<
ENGINE HOOD
\
MOULDING -
ONLY W ITH V IN Y L
ROOF OPTIONS
" DRIP MOULDING -REAR
(J)
::I:
MOULD I NG-
ENGINE HOOD ~/ m
MOULDING - ~
(ONL Y WITH VINYL ROOF
~
--- ~._-_::::::.:t ----=- AND D99 OPT IONS
------------
~k ~~ ---- MOULD I NG -W I N D OW
~
r
FRAME R EAR
MOULDING-WINDOW
FRAME U PPER
ll
)>
(
c
MOULD I NG- MOULDING -W I NDOW ~
MOU L DING- DOOR BEL T REV EAL F RAME FRON T 0
HEAD LAMP
MOULD I NG - ll
WINDOW
LOWER
MOULD I NG- j
HEAD L AMP U PPER
I
\
MOU LDI NG R EAR
COM PAR T M ENT LID
FRAME REAR
"-
ll
r-
r-
m
MOULDING- I QO
HEADLAMP LATERAL J
m
c
EMBLEM -REAR ~
COMPARTMENT LID "'tJ
m
ll
m
)>
MOU LDI NG-BACK PANEL
ll
(J)
MODE L 8VX 69
Figure 1-73
Exterior Ornamentation
--- ~~-----------------------
ADHESIVE BACKED NAMEPLATES INSTALLATION

1. To ensure secure retention of adhesive back namep- Locate protective st rip over clips and press strip in to
lates, it is important that the panel surface is thro - position .
roughly c leaned to remove al l traces of wax or oth er
co ntaminants. Wipe area of panel to which nameplate
is to be app lied with Prepsol or an equivalent clean in g
agent prior to installati on of nameplate. MOULDINGS - DRIP GUTTER
2. In addition, to achieve an effective bond between
nameplate and panel , panel surface shou ld be warmed REMOVAL
to minimum of 20 degrees C to 30 deg rees C. 1. To remove front section of drip moulding remove
3. To install namep late , mark co rrect location of name- screws attaching mould ing to windshield fram e as
plate on panel , remove protective back ing st rip and shown Fig. 1-7 6.
firmly press nameplate to panel.
4. Any nameplate which shows evidence of bond failure 2. To remove centre section of drip moulding prise
must be rep laced with a new nameplate. moulding away from retaining clips located over drip
gutter Fig . 1-77.
PROTECTIVE STRIPS - BODY SIDE 3. To remove rear section of drip moulding , prise
moulding away from body panel as shown Fig . 1-7 8.
The body sid e protective strips are sec ured by plactic c lips
whi ch are re tained in posi ti on by weld studs located along
body sid e panel s as shown in Fig . 1-75.
INSTALLATION
REMOVAL Reverse removal operations. Seal around sc rew attaching
Protect paint finish and prise moulding away from body holes prior to instal ling front drip moulding to wind shi eld
panel. frame :
CLI ~
/ DRILL 2,39+0,10 mm DIA. HOLE

-0,00
ON tOF MOULDING AS CLOSE AS
POSSIBLE TO WELD STUD LO CAT IONS
SC REW
SP2495. SCREW.
SECTION C·C SECTION C-C

(26 PLACE S) (EMERGENCY USE ONLY)
SECTION D-D
/ SCREW SECTION F-F

(4 PLACE S)
VIEW [A]
SECTION E-E SECTION G-G

\2 PLAC ES )
(4 PLA CES ) ;p;
SECTION A-A SECTION B-B
Figure 1-74
Exterior Ornamentation Installation
I
!
S ECTIO N A-A
Figure 1-75
Protective Strip Installation
Figure 1-78
Figure 1-76
WINDSHIELD AND BACK WINDOW
INSERTS
REMOVAL
1. Usin g a suitabl e too l, ca refull y ease out esc utcheons
cove rin g end s of in se rts.
2. Usi ng th e same tool , remove upper, lower and sid e
in serts from chann el.
INSTALLATION
1. Commencing at co rn er of wind shi eld or bac k wind ow,
place edge of in se rt into chann el and using a !;> Uitabl e
tool, lift oppos ite lip of rubb er chann el over inse rt.
Proceed prog ress ively around chann el until in se rts are
co mpl etely install ed in chann el.
2. Using th e sam e procedure, in stall co rn er esc utcheo ns,
en surin g that end s of in se rt s are co mpl etely cove red
by th e esc utcheons.
NOTE : Refer to wind shi eld and rea r win dow glass in -
stall ation in stru cti ons for detail s of inse rt remova l/
Figure 1-77 in sta ll ati on too l.
SHEETMETAL
INDEX
SHEETMETAL- DESCRIPTION ..................................... 01-55 ENGINE HOOD ................................................................. 01-57
FRONT FENDER ASSEMBLY ........................................ 01-56 REMOVAL .................................................................. 01-57
INSTALLATION .......................................................... 01-56 ADJUSTMENT ............................................................ 01-57
FRONT PANEL ASSEMBLY ........................................... 01-56 ENGINE HOOD LOCK RELEASE ................................. 01-58
REMOVAL .................................................................. 01-56 REMOVAL .................................................................. 01-58
DESCRIPTION
Front end sheet metal components consists of front fender, The hood lock release lever mounted beneath the RH side
front end panel, and engine hood assemblies. The engine of the instrument panel , controls th e hood lock release
hood assembly is hinged at the rear end and is supported spring . The engine hood , when relea sed from the locked
in th e open pos ition by a rod attached to the upper front position, engages in a secondary safety ca tch whi ch can
panel. be released by inserting fingers beneath lead in g edge of
engine hood to operate the catch .
FRONT FENDER ASSEMBLY
REMOVAL
1. Remove front bumper bar assembly. Refer Bumper Bar
removal instructions.
2. The front fenders are attached at locations shown
Fig . 1-79 .
3. Remove sc rews attaching fender to front lower skirt
panel. Refer 'A' Fig . 1-80.
4. Remove screws attaching fender to wheelhouse. Refer
'B' Fig . 1-81 .
5. Release shroud lower trim panel and remove screws
attaching rear flange of fender to body pillar . Refer 'C'
Fig . 1-82.
6. Remove screw '0' attaching lower part of fender to the
sill panel and screw attaching upper co rner of fender
to door frame. Figure 1-81
INSTALLATION
Pri or to installation of the front fender, apply seale r between
mating surfaces of body pillar, wheelhouse and fender.
___ c
•
Figure 1-82
Figure 1-79
FRONT PANEL ASSEMBLY
REMOVAL
1. Remove headlamp, radiator grill e and bump er ba r
assemblies. Refer respect ive sec tions for rem oval
details.
2. Remove screws attaching lower baffle to fron t panel
and c rossmember. Fig. 1-83.
3. Remove screws attaching th e front lower panel to

fenders and separate the front panel from wheelhou se
at welded joins. Fig . 1-84
INSTALLATION
Straighten flanges of wheelhouse panels , locate front end
panel and weld into posi ti on as shown Fig . 1 -85 .
Figure 1-80 Reverse remo val operations.
ENGINE HOOD
REMOVAL
1. Raise engine hood and scribe location of hin ge arm on
hood inner panel to facili tate in stall ati on.
2. Support the engine hood and remove bolts attac hing
hinges to engine hood . Fig. 1 -86.
3. To rem ove the engine hood hinge arm , remove bo lt
attaching hinge to body as ill ustrated Fi g. 1-87.
INSTALLATION
Reve rse re moval operati ons .
ADJUSTMENT
Wh en adjusting engi ne ho od, it is important th at uniform
spacing and ali gnm ent between hood and adjacent parts
be maintained . Slotted holes in engin e hood hin ge arm s
provide ad ju stm ent for re ar of engin e hood . Vert ical ad-
Figure 1-83 j ustm ent of fro nt of engin e hood ca n be achi eved by ad-
justin g the rubb er bumpers located at fron t edge of hood
'A' Fig . 1-88, in co njun cti on with th e adj ustabl e engin e
hood loc k bolt 'B'.
Figure 1-84
Figure 1-86

01 -58 BODY, SHEETMETAL, RADIATOR GRILLE&. BUMPER BARS
ENGINE HOOD LOCK RELEASE
REMOVAL
1. Remove radi ator front shroud. Di sconn ect engin e hood
release ca bl e from retainin g clips and di sengage end
of cabl e from th e hood hood loc k release spring. Refer
Fig. 1-89 .
2. From beneath RH side of instrum ent pan el slid e hood
release lever rea rward and disengage lever from panel
an d pull cable into vehic le.
INSTALLATION
Reve rse removal operat ions.
Figure 1-88
APPLYBODYHA RD WARE
GREAS E INSI D E O F
Ill ~~.:.MjJll
PLUNGER GU IDE TO A . NO CLEA RANCE
OJ
-g/'
DEPTH L EV EL WI TH ' . . PERMISS IBLE BETW EEN
REL EAS> 5eR,NG~ - ~-:~\)/' HOOO R ELE ASE SPR ING
0
c
II & NIPP LE ON ASSEM B LY .
~-<
A CJ)
I
j ,~ II/ VIEW[§]
LL- ~ --"-~
:I:
m
I jlt
~ ~OOCABLEASM ~
t 3:
I
\
0
5' ,
i
VIEW [QJ
~
Io 1'. l,l\ ~ / GROMMET - MA IN WIR ING
HARNESS r
SECTION D-0 J:J
)>
; HOOD SU PP ORT
c
HOOD RELEASE _)
a
J:J
CAB L E G')
I
r HOOD SUPPORT RETAINER.
r scREW A VIEW !A]

-J:J
r-
r-
SECTI ON A-A m
~LIP Qo
OJ
\\ --;, -,::] c
:s:::
"tJ
SE CT ION C-C SECTION 8-8 _ ;t'=' ::['''' -- J m
J:J
OJ
VIEW[g . )>
LG 3,6-4 ,6 Nm
J:J
CJ)
0
......
I
Figure 1-89 (J1
Engine Hood Release & Support Installation CD
NOTES
RADIATOR GRILLE
INDEX
Subject Page
DESCRIPTION ................................................................... 01-61
REMOVAL .................................................................. 01-61
INSTALLATION .......................................................... 01-61
DESCRIPTION
Th e radiator grill e illustrated Fig. 1-90 is made from radiator support and lift grill e away from gromm ets located
mould ed plasti c with chrome plated fini sh. Design and in th e lower fron t panel. Refer Fig. 1-90.
paint out variati ons distinguish grill es for indi vid ual models.
INSTALLATION
REMOVAL Reverse removal operati ons.
Remove sc rews attaching th e radi ator gril le to th e upper
\
NUT
I (2 PLACES)
RAD IATOR GRILLE
GROMMET
Figure 1-90
Radiator Grille Installation
NOTES
BUMPER BARS
INDEX
S u~ ect Page Subject Page
FRONT BUMPER BAR ASSEMBLV .............................. 01-63 REAR BUMPER BAR ASSEMBLY ................................ 01-63
REMOVAL .................................................................. 01-63 REMOVAL .................................................................. 01-63
INSTALLATION .......................................................... 01 -63 INSTALLATION .......................................................... 01-63
FRONT BUMPER BAR ASSEMBLY REAR BUMPER BAR ASSEMBLY
REMOVAL REMOVAL
1. From beneath front fenders remove bolts attaching 1. Disconnect rear licence plate lamp wiring .
bumper support brackets to frame as shown Fig. 1-91 2. From inside the rear compartment remove the four
and bolts securing ends of bumper to fenders bolts attaching the bumper to the rear end panel.
Fig. 1-92. Fig. 1-93.
2. Ease bumper assembly forward and away from front
end panel. INSTALLATION
INSTALLATION Reverse removal operations .
Reverse removal operations. NOTE: Prior to installation of bumper assembly ensure that
sealing washers are correctly located between bumper
mounting brackets and body.
Figure 1-91
Figure 1-93
Figure 1-92
SPECIAL TOOLS
Tool No KM-125 Trunk Lid Hinge Spring Removal and

Installation tool
Figure 1-94
Tool No KM-206-01 Trunk Lid Lock Cylinder Retaining Spring

Installation tool
Figure 1-95
Tool No AU170 Door Hinge Pin Removal Tool
Figure 1-96
VENTILATION, HEATING & AIR CONDITIONING 02-01
SECTION 02
VENTILATION, HEATING & AIR CONDITIONING
Subject Page
VENTILATION- HEATING .............................................. 02-01
AIR CONDITIONING ......................................................... 02-11
VENTILATION - HEATING
INDEX
Subject Page Subject Pa,ge
DESCRIPTION ................................................................... 02-01 HEATER AIR OUTLETS - OUTER ................................ 02-07
HEATER ASSEMBLY ....................................................... 02-04 REMOV AL .................................................................. 02-07
INSTALLATION .......................................................... 02-06 HEATER CONTROL ......................................................... 02-08
HEATER BLOWER MOTOR ........................................... 02-06 REMOVAL .................................................................. 02-08
INSTALLATION .......................................................... 02-06 GRILLE - VENTILATION EXHAUST ............................. 02-08
HEATER CORE ................................................................. 02-07 REMOVAL .................................................................. 02-08
INSTALLATION .......................................................... 02-07 HEATING & VENTILATION SYS. COMPONENTS ..... 02-09
DESCRIPTION
The ventilation and heating system featured on 'VB ' models is controlled by the temperature lever which operates the
allows fresh or mixed hot and cold air to flow through the mixture flap. This regulates the volume of air passing
vehicle. (Fig. 2-1 ). through the heater core. (Fig. 2-3).
Air enters the grille at the rear of the engine hood and
A high capacity blower is used for ventilation and heating .
passes through the vent il ation and heating system into the
With the blower in operation the volume of air can be
vehicle. The air is then exhausted from the vehicle through
adjusted by selecting any of four speeds to suit individual
a vent grille located at each side roof extension panel.
requirement.
(Fig. 2-2)
The heating system utilises an air-mix principle where the The air flow to the floor space and demist vents is con-
temperature of the air entering the passenger compartment trolled independently by the centre levers. (Fig. 2-4).
Figure 2-1
Body Flow Through Ventilation
02-02 VENTILATION, HEATING & AIR CONDITION!NG
~ · ·. . n
]I -- . -1
Figure 2-2
Body Ventilation
The four outside vents supply co ld or heated air in ac-

co rdan ce with the temperature lever setting. Th e in-
depend ently adjustable outboard upper vents can be set Figure 2-4
to direc t co ld air to th e passenger's and driver's fa ce during
warm weath er operati on. (Fig. 2-5). During winter th e vent
can be adj usted to direct heated ai r outwards to demisi th e
front door wind ow glass. The lower outer vent can be
directed to fl ow warm ai r along th e door interior pan els and
through the vehi cle.
Figure 2-3
Heating and Ventilation System
Figure 2-7
Figure 2-5
In addition to air entering vehi cle by way of the ai r-mix

system , fresh air is circulated from the two vents located
in the centre of the instrument panel. Fresh air is duel ed
into th e passenger co mpartment through thi s separate air
An adju stment wh ee l located below th e vents reg ulates air system , independe heating system. (Fig . 2-6) .
distribution .
Adj ust wheel as fo ll ows:-
The volume of air at the centre vents can be regulated by
Right -Shuts off air flow.
an adjusting wheel on each vent. Th e vent in serts can be
Centre -Upwards air fl ow. rotated and the adjustable fins set to direct air flow as
Left -Upwards and downward s air fl ow. required . (Fig . 2-7) .
Figure 2-6
Ventilation System
02-04 VENTILATION, HEATING & AIR CONDITIONING
HEATER ASSEMBLY
REMOVAL:
1. Remove hood weatherstrip 'A' and water deflector 'B'
from upper cowl panel. (Fig. 2-8).
2. Disconnect blower motor wiring at plug 'C' and remove
screws attaching blower cover 'D'. (Fig. 2-9).
3. Remove heater hoses from heater core tubes.
(Fig . 2-1 0).
4. Remove transmission tunnel console, ashtray and
heater case cover 'E'. (Fig. 2-11).
5. Remove heater control unit cover pad 'G'. (Fig . 2-12).
6. Disconnect heater control levers 1, 2, 3 and remove
screw attaching heater control panel 'H ' and lower
section of instrument panel 'X'. (Fig. 2-13). Disconnect
radio.
7. Disconnect electrical wiring from heater control unit Figure 2-9
'H'. To facilitate installation note order of wiring con-
nectors as shown. (Fig. 2-14 ).
1 - Orange
2 - Black
3 - Tan
4- Yellow
5 - Grey
8. Remove centre air vent and auxiliary switch panel.
NOTE: To remove switch panel, prise right and left hand
switch or cover from panel to gain access to attaching
screws. Refer Fig . 2-14A. Remove demist air ducts 'L'.
9. Remove screws attaching upper and lower sections of
steering column cover. Remove instrument pan el
compartment and instrument panel lower trim panels.
1 0. Remove air distribution ducts. Remove screw located
at front centre of air distribution housing and prise
retaining clips ' N' from housing. Remove housin g away
from dash panel as shown Fig. 2-15.
11. Remove nuts 'X' retaining blower motor hou sing
(Fig . 2-16) and remove housing downward away from
Figure 2-10
dash panel as shown. (Fig. 2-1 7)

Figure 2-14 A
Figure 2-12
r .. i i.i i i i i '

1~
Figure 2-17
Figure 2-19
INSTALLATION :
1. Reverse removal operations.
2. Ensure that electrical connections are installed to
heater control unit in correct sequence as shown
(Fig. 2-14) prior to installation of control unit.
1 - Orange
HEATER BLOWER MOTOR
2 - Black
3- Tan
REMOVAL:
4 -Yellow
1. Remove blower motor housing as described HEATER
5 - Grey ASSEMBLY removal.
3. Set heater control levers to bottom stop of control unit 2. Prise off clips retaining cover to blower motor housing.
(Fig. 2-18) and connect the control operating rods to (Fig. 2-20).
the air distribution housing.
Connect operating rods in the following order. 3. Remove screw retaining motor and blowe r to ho using.
(Fig. 2-19) . (Fi g. 2-2 1).
1. Long rod for heater air mixt ure.
2. Short rod for downward air distribution. INSTALLATION :
3. Medium length rod for upward air distribution. Reverse removal operations.
. "
.Ill
HEATER AIR OUTLETS - OUTER
REMOVAL:
1. Pri se upper and lower air outlet inserts away from
outlet housing as shown. (Fig. 2-23)
2. Remove screws attaching outlet housing to instrument
pan el pad. (Fig. 2-24).
INSTALLATION:
Reverse rem oval operations.
Figure 2-21
HEATER CORE
REMOVAL:
1. Remove air distributo r housing as desc ribed in
HEATER ASSEMBLY removal.
2. Pri se off clips re taining upper and lower sec ti ons of air
distribu tor housin g and di sco nnect operat ing rod 'X'.
3. Separate housing and remove heater co re . (Fi g. 2-22).
INSTALLATION : Figure 2-23
Reverse removal operation s.

HEATER CONTROL GRILLE - VENTILATION EXHAUST
REMOVAL: REMOVAL:
1. Remove heater control unit cover pad. 1. The ventilation grille is retained by pin s moulded into
2. Disconnect heater control levers 1 - 2 - 3 and remove the back facing of the grille. These are inserted into
screw attaching heater control unit to instrument panel. grommets located around the exhaust recess. To re -
(Fig. 2-25). move the grille, prise grille away from exhaust re cess
using a screwdriver or suitable tool
3. Disconnect electrical wiring from heater control unit.
2. The grille lower moulding is retain ed by sc rews located
To facilitate installation note order of wiring con-
behind the grille as illustrated. (Fig. 2-26).
nectors.
INSTALLATION : INSTALLATION :
1. Reverse removal operations. Reverse removal operations. Apply sealer around sc rew
2. Ensure that electrical connec tions are installed in attaching holes and grommets prior to installation of
moulding and grille.
correct order prior to installation of control unit. Refer
to HEATER ASSEMBLY installation for wiring sequ-
ence.
3. Set heater control levers to bottom stop of control unit,
and connect the cont rol operating rods to the air
distribution housing. Connect operating rods as fol-
lows:
a. Long rod for heater air mixture
b. Short rod for downward air distribution .
c. Medium length rod for upward air distribution.
Figure 2-26
Figure 2-25
HEATING & V ENTILATION SYSTEM COMPONENTS
<
m
z
- ~
®
~
E
0
®' ~'-
a~ , @ ~
~ I
:::r:::
~ ~ ::...: , ;&;-z--.___~~~f'- @ ~ m
@ ® @
~)-,
~~
® ~
~
l l'-
c
acb
I
' ~ .
61)
;;z
G')
~ ;,&- , @ ~~ , ~y
-J
Qo
@ ® ~
JJ
HOUSING ASSEMBLY - Chamber, lower
2 HOUSING ASSEMBLY - Chamber , upper
0 (')
0
3 FLAP ASSEMBLY
4 FLAP ASSEMBLY
5 FLAP ASSEMBLY
6 CORE ASSEMBLY
15 CONTROL ASSEMBLY- Heater
16
17
G)
LEVER ASSEMBLY- Temperature control
LEVER ASSEMBL Y - lnterior control
24
25
26
HOSE - Air outlet , outer R H
HOUSING-Air outlet, outer
HOSE - Nozzle demist
-- ' --.
30
31
@
INSERT -Centre
INSERT- Outer
0
z
c
~
0
7 HOUSING -Heater blower 18 LEVER ASSEMBLY - De mist control 27 NOZZLE- Demist outlet 33 GASKET - Heater core ~
8 BLOWER ASSEMBLY 19 LEVER ASSEMBL Y-Biower switch control 28 HOSE - No zzle centre outlet 34 CLAMP- Hose z
G')
14 CLAMP- Upper to lower heater housing 23 HOSE-Air outlet, outer LH 29 HOUSING- N oz zl e centre air outl et 35 HOSE - Water
0
1\)
I
Figure 2-27 0
Heating & Ventilati on System Components CD
NOTES
AIR CONDITIONING
INDEX
Subject Page Su~ect Pag e
GENERAL DESCRIPTION ............................................... 02-12 PURGING THE SYSTEM ................................................. 02-31
AIR CONDITIONING CONTROLS ................................. 02-13 CHECKING COMPRESSOR OIL LEVEL &
BLOWER CONTROL ................................................ 02-13 ADDING OIL ...................................................................... 02-32
TEMPERATURE CONTROL .................................... 02-13 EVACUATING AND CHARGING THE SYSTEM ......... 02-32
MODE SELECTOR .................................................... 02-14 PRELIMINARY OPERATIONS ................................ 02-32
MODES OF OPERATION ................................................ 02-i4 EVACUATION EQUIPMENT CHECK ..................... 02-32
SYSTEM 'OFF' ........................................................... 02-1 4 EVACUATION & CHARGING LINE
SYSTEM ON MAXIMUM AIR CONDITIONONG CONNECTIONS ......................................................... 02-33
COLD ........................................................................... 02-14 INITIAL EVACUATION AND LEAK TEST ............ 02-33
SYSTEM ON NORMINAL AIR CONDITIONING LEAK TEST AND PURGE ....................................... 02-33
COLD ........................................................................... 02-14 FINAL EVACUATION ............................................... 02-33
COMBINATION STAGE, HEATING / AIR FINAL CHARGE ........................................................ 02-33
CONDITIONING Bl LEVEL ..................................... 02-14 COMPONENT PART REPLACEMENT AND
VENTILATION ............................................................ 02-14 ADJUSTMENT ................................................................... 02-34
HEAT ........................................................................... 02-14 PREPARING SYSTEM FOR REPLACEMENT
DEMIST ....................................................................... 02-14 OF COMPONENT PARTS ....................................... 02-34
CCOT REFRIGERATION SYSTEM ................................ 02-22 Refrigeration System Open to
REFRIGERATION CYCLE ........................................ 02-22 Atmosphere ........................................................ 02-34
DESCRIPTION & OPERATION OF Collision Service ............................................... 02-34
CCOT SYSTEM COMPONENTS ............................ 02-22 Foreign Material In System ............................. 02-34
Liquid Line .......................................................... 02-22 REFRIGERANT LINE CONNECTIONS .................. 02-36
Expansion Tube (Orifice) ................................ 02-23 '0 ' Rings .............................................................. 02-36
Thermostatic Switch ......................................... 02-23 Hose Clamps ...................................................... 02-36
Accumulator ....................................................... 02-23 REPAIR OF REFRIGERANT LEAKS ..................... 02-36
Evaporator .......................................................... 02-23 Leaks At '0' Ring Connections ..................... 02-36
Condenser .......................................................... 02-23 Leaks At Hose Clamp Connections ............. 02-36
Compressor ........................................................ 02-23 Compressor Leaks ............................................ 02-36
Clutch-Pulley ...................................................... 02-23 Refrigerant Hose Leaks ................................. 02-36
Clutch Coil .......................................................... 02-23 COMPRESSOR SERVICE ........................................ 02-36
Cylinder Block ................................................... 02-23 False Compressor Seizure .............................. 02-37
Pistons ................................................................. 02-23 Compressor Replacement ............................... 02-37
Compressor Connector ................................... 02-23 Compressor Failure .......................................... 02-37
Pressure Relief Valve ....................................... 02-25 Compressor Removal ....................................... 02-37
LUBRICATION ........................................................... 02-25 Compressor Installation ................................... 02-37
REFRIGERANT HOSES & LINES .......................... 02-25 Compressor Drive Belt Tension
REFRIGERANT .......................................................... 02-25 Adjustment ......................................................... 02-37
Precautions in Handling R-12 ........................ 02-25 Compressor - Partial Removal and
SERVICE OPERATIONS ................................................. 02-29 Installation .......................................................... 02-37
INTRODUCTION ................................................................ 02-29 Removal .............................................................. 02-37
MAINTAINING CHEMICAL STABILITY IN Installation .......................................................... 02-41
THE REFRIGERATION SYSTEM ................................... 02-29 CONDENSER ............................................................. 02-41
THE PRIMARY CAUSES OF SYSTEM FAILURES .... 02-29 Removal .............................................................. 02-41
LEAKS ......................................................................... 02-29 Installation .......................................................... 02-41
HIGH TEMPERATURE AND PRESSURE ............. 02-29 ACCUMULATOR ASSEMBLY ................................. 02-41
AIR IN THE SYSTEM ................................................ 02-29 Removal .............................................................. 02-41
POOR CONNECTIONS ............................................ 02-30 Installation .......................................................... 02-41
RESTRICTIONS ......................................................... 02-30 THERMOSTATIC SWITCH ....................................... 02-41
DIRT ............................................................................. 02-30 Removal .............................................................. 02-41
CORROSION .............................................................. 02-30 Installation .......................................................... 02-41
MOISTURE .................................................................. 02-30 BLOWER ASSEMBLY .............................................. 02-41
PRECAUTIONS IN HANDLING REFRIGERANT Removal .............................................................. 02-41
LINES .................................................................................. 02-30 Installation .......................................................... 02-42
LEAK TESTING THE SYSTEM ...................................... 02-31
Subj ec t ....................... ... .. .. ........ .. ........ ............................. Page Subj ect ..................... . ............. .... Page
AIR INLET ASSEMBLY ............................................ 02-42 PERFORMANCE TEST .................................................... 02-48
Removal .............................................................. 02-42 PROCEDURE ............................................................. 02-48
Installation .......................................................... 02-42 PERFORMANCE OAT A ........................................... 02-49
HEATER & EVAPORATOR ASSEMBLY .............. 02-42 REFRIGERANT CIRCUIT TROUBLE DIAGNOSIS
Removal .............................................................. 02-42 GUIDE ................................................................................. 02-51
Installation .......................................................... 02-42 INSUFFICIENT COOLING QUICK-CHECK
EVAPORATOR CORE .............................................. 02-48 PROCEDURE ............................................................. 02-51
Removal .............................................................. 02-48 THERMOSTATIC SWITCH DIAGNOSIS ................ 02-51
Installation .......................................................... 02-48 ACCUMULATOR ASSEMBLY ................................. 02-51
HEATER CORE ......................................................... 02-48 CONDENSER ............................................................. 02-51
Removal .............................................................. 02-48 EVAPORATOR .......................................................... 02-51
Installation .......................................................... 02-48 REFRIGERANT LINE RESTRICTIONS .................. 02-51
EXPANSION TUBE (ORIFICE) ............................... 02-48
Removal .............................................................. 02-48
Installation .......................................................... 02-48
GENERAL DESCRIPTION
An integrated air conditioning system is standard on th e enters the system and is forced through th e system by th e
8VX Sedan and is optional on all other model s. The in- bl ower. As the air passes through the evaporator co re, it
teg rated system combines both th e heating and cooling receives maximum cooling if the air co nditioning co ntrols
functions in a single unit. Refer Fig. 2- 28 . are calling for cooling. After leaving th e evaporator, th e air
enters the Heater and Air Conditioner Connecting Duct
The vehic le interior can be heated , coo led or ven ted (o r a Assembly where , by means of a diverter door, it is ca used
comb ination of these operations) depending on the posi- to pass through or to bypass th e heater core in the pro -
tion of the two slide con trol levers and the rotary mode portion s necessary to provide the des ired outl et tem per-
switch . ature. Dependant on rotary mode swi tch position
Air entering the vehicle must pass through the cooling unit co nd iti oned air then enters th e vehicle through ei th er th e
(evaporator) and through (or around) the heating un it in fl oo r distribution ducts or th e dash outl ets.
that ord er, the system is thus referred to as a 'reheat' Wh en, during coo ling operati ons, the air is cooled by the
system. evaporator to below comfort level , it is then warmed by the
The evaporator provides maximum cooling and de- heater to the desired temperature . During 'heating only '
humidifying the air passi ng through the co re when the air operations the refrigerati on system will not be in operation
conditioning system is call ing for coo lin g. System operation and ambient air will be warmed to th e desired leve l in the
is as foll ows: Air, ei th er outside air or reci rculated air, sa me manner.
CONDENSER SCREEN
HEATER CORE
EVAPORATOR CONNECTIONS
DEMIST DOOR
EVAPORATOR AIR
ACTUATOR OUTLET
0 0
Figure 2-28
Evaporator and Heater Assembly
-...J~--F AN
AIR CONDITIONING CONTROLS CONTROL
BLOWER CONTROL
The four speed blower fan is controlled by the right hand
lever in the slide control assembly in the centre of the
instrument panel assembly. (Refer Fig. 2-29). When this
control is at the ' LOW ' position the fan is operating on the
lowest setting and will operate whenever the ignition is
switched on and the mode selector is turned from the off
setting.
TEMPERATURE CONTROL
HEAT CONTROL
Air outlet temperature can be adjusted independantly of
any of the air conditioning modes that are chosen on the
mode selector switch. The air temperature control slide is
the lever on the left of the slide control assembly in the
centre of the instrument panel. It is connected to the heater Figure 2-29
diverter door by a bowden cable. (Refer Fig . 2-29) Fan and Temperature Controls
MODE SELECTOR (Refer Fig. 2-30) SYSTEM ON NORMAL AIR CONDITIONING COLD
The mode selector is a rotary type combination vacuum (Fig. 2-33)
and electrical control and is situated to the right of the Mode control set on white snowflake.
blower and temperature control levers. Engine vacuum is
Fan is on.
directed through a system of ports in the selector body to
the various air door actuators. This selector also has Compressor is switched on.
electrical contacts to activate the compressor clutch during Recirculation door closed; outside air is drawn through
the three modes requiring refrigeration. The control knob blower and forced through evaporator.
can be rotated to any one of seven positions to give the Heater door is closed (can be set to any desired position
following basic air conditioning / heating modes. if needed).
Upper level doors are open and fresh refrigerated air is
directed through upper level vents.
BI - LEVEL
Normal A/c. Heat COMBINATION STAGE, HEATING / AIR
Max . cold \ Ventilate
CONDITIONING Bl LEVEL (Fig. 2-34)
Mode control set at Blue/Red rectangle .
Fan is on.
Demist Compressor is switched un.
Recirculation door is closed.
Outside air is drawn through the blower and forced through
evaporator.
Heater door at mid setting.
Upper level lower door open.
Warm air is biased to lower level, cooler air is delivered
through upper level vents.
VENTILATION (Fig. 2-35)

Mode control set on green square.
Figure 2-30 Fan is on.
Mode Selector
Recirculation door is closed . Outside air is drawn through
blower and forced through the evaporator (compressor is
switched off).
Both upper level doors are open and fresh air can be
diverted through the heater core or directed straight into
the upper level ducts.
MODES OF OPERATION HEAT (Fig. 2-36)

Mode Control set on inverted white triangle .
SYSTEM 'OFF' (Fig. 2-31) Blowe r fan is on.
Mode control set on 0. Recirculation door is closed; outside air is drawn through
Blower fan is off. blower and is forced through the evaporator (Compressor
Compressor is switched off. is switched off).
Recirculation door is closed, outside air flows through Both upper level doors are closed and major volume of air
blower and forced through evaporator and is delivered to is directed to the floor area outlet.
the floor outlet. Temperature is controlled by the angle of the heater air
door which varies the amount of air directed through the
heater core .
SYSTEM ON MAXIMUM AIR CONDITIONING COLD
(Fig. 2-32) DEMIST (Fig. 2-37)
Mode Control set on blue snowflake. Mode control set on white triangle.
Blower fan is on. Blower fan is on.
Compressor is switched on . Recirculation door is closed; outside air is drawn through
Recirculation door is open 80 percent of inside air and the blower and is forced through the evaporator (Com-
20 percent outside air is drawn through blower and forced pressor is switched off).
through evaporator; upper level doors are open and re- Both upper level doors are closed and major volume of air
circulated refrigerated air is delivered through upper level is directed through! the demisi ducts.
vents. Temperature is controlled by the angle of the heater air
NOTE: The heater door can be controlled independantly of door which varies the amount of air directed through the
the mode selector to raise outlet temperature . heater core.
OUTSIDE AIR
MODE SWITCH (
L
\1
0
V A CUUM TANK
E3
**
VA CUUM SOURCE
FROM ENG IN E
BLACK l a~
'
'
,-- --
e
""-
- --
RE CIRC DOOR
--
=-J 1 2 3 4 5
'
'
ORANGE
BLUE
:I
:
k DEMIST DOOR
LIGHT BROWN
UPP ER ;[}
II MODE DOOR
II
I
I LOW ER
MODE DOOR
jU} PINK
Figure 2-31
Off Positio n
UPPER LEVEL DUCTS
RECIRCULATED
AIR
AIR INLET
MODE SWITCH l
6
I \1
0
VACUUM TANK j.
a
T **....,_
VACUUM SOURCE
-
FROM ENGINE
r---- "'
"'"' ==
--:::;:::;>
Jl
=-J 1 2 3 4 5
I
0
((
e RECIRC DOOR
=--::;?
:
'
'
ORANGE
BLUE
'
A DEMIST DOOR
:\
II
UPPER
MODE DOOR
® LIGHT BROWN
II
1:
PINK
'
' LOWER I
MODE DOOR
Figure 2-32
System on Maximum Cold
UPPER LE VEL DUCTS
OUTSIDE AIR
MODE SWITCH l
6
I \1
0
B
VACUUM TAN K
*-..--
VACUUM SOURCE
l *0
~J
FROM ENGINE
BLACK
1 2 3 4 5
.-- - ""'" -- -- --
rr
e RE CIRC DOOR
:
''
ORANGE
BLUE
:I
:
A DEMIST DOOR
LIGHT BROWN
II UPPER
II MODE DOOR
II
1:
PINK
'' LOWER
MODE DOOR
Figure 2-33
System on Normal Air Conditioning Cold
UPPER LEVEL DUCTS
INTERIOR
MODE SWIT CH f'

6
\1
0
VACUU M TANK
a..-
**0
VACUUM SO UR CE
FROM ENGINE
BLACK
~
I.
1 2 3 4 5
--
e
,.
-- --~
RECIRC DOOR
-- =-=2--_j
:
''
ORANGE
BLUE
:j
:
k DEMI ST DOOR
I
UPPER
MODE DOOR
® LIGHT BR OWN
I:
~
I
PINK
I LOWER
MODE DOOR
Figure 2-34
Combination Stage - Heating Air Conditioning - Bi Level
UPPER LEVEL DUCTS
OUTSIDE AIR
DEMIST DUCTS
DE MIST
__._-+-+~._-+-
MODE SWITCH l
6.
o\1....
VACUUM TANK
E3
**0
VACUUM SOURCE
FROM ENGINE
~--~~~
J
- ~--~-~~~--~~~J
J,
2 3 4 5
rre RECIRC DOOR
ORANGE
BLUE
'
:I
.A DEMIST DOOR
~
LIGHT BROWN
UPPER
MODE DOOR
I
~ LOWER
MODE DOOR
,
PINK
~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .~
Fig. 2-35
Ventilation
UPPER LEVEL DUCT S
A I R INLET
INTER IOR
MO D E SWITCH
6
\7.....
0
VACUUM T ANK
E3
**0
V A CUUM SOURCE
~
~-J
FR OM ENGINE
BLACK
-- ,..
1 2 3 4 5
-- --
rr- e ~ --
RE CIR C DOOR
~--
'
'
''
ORANGE
BL UE
:j
:
k DEMIST DOOR
LI GHT BR OWN
I
UPPER
MODE DOO R
®
I: PINK
I
' LOWER
MODE DOOR
Figure 2-36
Heat Mode
02-21 VENTILATION, HEATING & AIR CONDITIONING 02-21
UPPE R LE VEL DUCTS
DEM IST DUCT S
AIR INLET
MODE SWIT CH ' l::J,.-

\1
0
V A CUU M T AN K
E3
**0
VA CUUM SO URCE
FR OM EN GINE
BLACK l
fr$
:
~ --
t:>.
-- -- ~ -
RE CIR C DOOR =-=J 1 2 3 4 5
'
'
ORANGE
BLUE
:I
:
.! DEM IST DOOR
LIG HT BROWN
I
UPPER
MODE DOOR
®
I
r' LOWER
PINK
'
MODE DOOR
Figure 2-37
Demist Mode
COMPR ESSOR C LU TCH GROUND L EA D
CO MPRESSOR
ACCUMU L ATOR
EVAPORATOR
DESICCANT (DRI ER)
TH ERMOSTAT IC
CZl HIGH PRESSURE VAPOR
CYCLING SW ITCH
- HI GH PRESSURE LIQUID
c:J LOW PR ESSURE LI QUID
c::::::J LOW PRESSURE VAPOR
+12 VOLTS
Figure 2-38
Schematic Of The CCOT System
CCOT REFRIGERATION SYSTEM Thi s liqui d flows th rough th e liqu id lin e to th e expansion
tub e (o rifi ce) wh ere it un de rg oes rapid expansion and
The refrigerat ion system in co rp orates a Cyc ling Clutch - chang es from a med ium temp erature, high pressure liqui d
Orifice Tube system; this desig n exhibits so me slightly to a low temperature, low press ure li quid and vapour
different charac teri sti cs to systems used on previ ous mixture. This cold , foamy mixture enters th e evaporator
Holden model s. core at the bottom end and flows through parallel tubes
A temperature sensi ng switch turn s th e co mpresso r on- upward through the core . Heat from th e warm airstrea m
and -off to prevent evaporator cond ensate freeze. Thus th e pass ing through the core is transferred to th e refri gerant,
compressor runs only as necessary. vapourizing the liquid and coo ling th e air. Un der hi gh load
During operati on in the ai r co nditi oning mode, slig ht in - conditions all the liq uid is vapouri zed in th e eva porator and
creases and decreases of engin e speed may be noti ced. only vapour fl ows to th e acc umul ator and through th e
This characteristic should be co nsi dered norm al as th e sucti on line to th e compressor wh ere hea t-laden va pour is
system is designed to cyc le the compresso r on and off to drawn into th e co mpresso r an d th e cyc le is repeated.
maintain desi red cooling . The intermittent co mpresso r Un der lighter load co nditi ons th e liquid and vapour is
operati on improves fuel economy. separated in the acc umul ator so th at only va pour is drawn
into th e co mpresso r.
Wh en the ign ition is turned off and the air co nditi onin g has
been opera ting, the refrigerant in the system will co ntinu e
to flow until press ure is equalized . Thi s may res ult in a fai nt
so und of liqui d fl owing for 30-60 seconds .
REFRIGERANT CYCLE DESCRIPTION AND OPERATION OF CCOT

Refer to Fig . 2-38 for a schematic illu strati on of the re- SYSTEM COMPONENTS
fri gerati on system showin g relati onship of co mponen ts.
The co mpressor discharges hi gh temperatu re, high pres- Liquid Line
sure vapour that co ntai ns heat abso rb ed in the evaporator. Th e small est diam eter refri gerant lin e in th e system, th e
Thi s vapour flows through two parall el tubes in th e con- hi gh press ure liquid line ca rri es th e hi gh press ure liqui d
dense r whe re it releases heat to th e airstrea m and changes refri gerant from the co nd ense r to th e ex pansion tub e
to a med ium temperature high pressure liq uid. (orifice)
Expansion Tube (Orifice) acti on of the cond enser converts th e high pressure re-
Th e plasti c ex pansi on tub e, with its mes h sc reen and frigerant vapour to high pressure liquid refri gerant.
orif ice, is located in a short length of pipe between th e
evaporator inl et pipe and th e liquid lin e conn ection. It Compressor
provid es resistance to th e hi gh pressure liquid refri gerant The prime purpose of the compresso r (Fig . 2-39) is to take
arriving through th e liquid lin e, actually controlling or th e low pressure refri gerant va pour pro duced by th e
metering th e fl ow of regrigerant to th e evaporator and al- evaporator and com press it into a high pressure, hi gh
lowing it to enter th e evaporat or as a low pressure liquid temperature vapour which wi ll be sent on to the condenser.
and vapour. It utilizes th e principl e that 'wh en a vapour is compressed ,
Th e expan sion tube and orifi ce are protected from con - both its pressure and temperature are raised.' Th e ax ial
taminati on by filt er sc reen s on both inl et and outlet sides. compressor is belt driven trom th e engin e through an
As no ad justm ent or repair is possi bl e, th e tube is servi ced electromagneti c clutch pull ey on th e co mp resso r.
only as an assembly. This co mpresso r has three doubl e-acti ng pistons, making
it a six cylinder compresso r.
Thermostatic Switch Identification of the compresso rs mu st be by model and
Th e cyclin g bellows-o perated thermostati c temperature serial number stamped on a pl ate located on top of th e
switch is attached to the evaporator case, with its metal compressor.
ca pill ary tub e c lamped to, and then in sulated around , th e
eva porator inl et pipe. Sens ing inl et pipe temperature Clutch-Pulley
change, th e switch engages/ di sengages th e compressor The movable part of the clutc h drive plate is in front of the
clutch to maintain proper evaporator temperature. pulley and bearing assembly. Th e arm ature plate, the
Th e switch al so acts as th e cold-weather compressor movable member, is attached to th e drive hub through
ambient switch. driver springs and is riveted to both members. Th e hub of
Th e th erm ostati c switch is pre-set to spec ifi cati on and the drive plate is pressed over a square drive key located
ca nnot be adjusted for servi ce . in the co mpressor shaft. A spacer and retainer rin g are
assembled to the shaft and th e assembly is held in place
Accumulator with a self-locking nut. The pulley rim, power elem ent rin g
and pulley hub are form ed into a fin al assembly by
Connected to th e evaporator outl et pipe, th e sea ler ac - moulding a frictional material between the rim and th e hub
cumulator assembly acts as a refrig erant storing contain er, with the power element ring imbedded in the forward face
recei ving vapour and so me liqu id and refri gerant oil from of the assembly.
th e evapo rator.
A two -row ball bearing is pressed into th e pull ey hub and
At th e bottom of th e accumulator is th e desi ccant, which held in place by a retai ner ring . Th e entire pull ey and
acts as a drying ag ent for moisture that may have entered bearing assembly is then pressed over th e front head of the
th e system . An oil bl eed hole is al so located near th e compressor and secured by a retain er ri ng.
bottom of th e acc umul ator outl et pipe to provid e an oil
return path to th e compressor. Clutch Coil
A low-sid e press ure valve se rvice fitting is located at th e The coil is moulded into th e coi l hous ing with a fill ed epoxy
top of th e acc umulator. resin and must be replaced as a co mpl ete assembly. Three
protrusi ons on th e rear of th e housi ng fit into alignm ent
Evaporator holes in the compressor front head. A retain er rin g sec ures
Th e evaporator, is located in th e HeaterI Evaporator the coil and housing in place. Th e coi l has 3.85 ohms
modul e mounted und er th e in strument panel. resistan ce at 26 deg. C ambi ent temperature and will re-
Th e evaporator co re, wh ich is aluminium and similar in quire no more than 3.2 amps at 1 2 vo lts DC. Since the
co nstructi on to th e ca r radiator, is the actual cooling unit clutch coil is not grounded internall y, a groun d lead is
of th e system. Th e bl ower forces air through the evaporator required as well as a 'hot' lead .
core wh ere it is coo led and dehumidified . Condensate,
wh ich co ll ects on th e co ld fin s of the cond enser, is allowed Cylinder Block
to drain from th e housing through a small hole in the The cylinder block consi sts of a front and a rea r half. Three
bottom. Unlike a radiator whi ch transfers heat to the air piston bores are line bored in each half durin g prod ucti on
fl owing through it, th e evaporator absorbs heat from th e to assure proper alignment and parall eli sm. Th e two halves
pass in g air. Th is is how th e air is cooled . Th e heat that is must be serviced as an assembly to assure correct re-
abso rb ed from th e air causes most of th e refrigerant to boil lationship of parts.
into a vapour.
This vapour th en fl ows out the top of th e evaporator and Pistons
into th e acc umul ator, carryin g with it some liquid refrig erant Th e cast alumin ium doubl e end pi stons have grooves to
and refrigerant oi l. receiv e Teflon pi ston rin gs. Two oil return passages are
drill ed from each ri ng groove. A notch in the cas ting web
Condenser of each piston identifies th e end of th e pi ston wh ich shoul d
Th e cond ense r is an alum inium an d co pper tube-a nd -fin be pos iti oned toward the front end of th e com pressor. A
heat transfer unit with stee l end pl ates for mounting located sph eri cal cavity is located on both inn er faces of each
directl y forward of the radi ator. piston to rec eive the piston drive balls.
Th e fun cti on of th e condense r is to transfer heat from th e
Compressor Connector
high pressure, hig h temperatu re refrig erant vapour dis-
charged by th e co mpresso r fl owing through its tubes to th e Compressor co nnectors are attached to th e co mp resso r
air stream drawn through its fin s by th e engin e fan. Th e rear head by means of a single bolt and loc k washer.
0
1\)
I
1\)
~
<
m
FRONT z
DISCHARGE VALVE PLATE :::f
TEFLO N PISTON RING
s
\"f
SHAFT SEAL ASM.
I L
SHELL 5
SHAFT ~z
PULLEY BEARING
:I:
m
~z
SUCTION SCREEN CLUTCH PLATE
AND G)
HUB ASSEMBLY
Qo
~
RETAINER RING JJ
(")
SEAL SLEEVE 0
z
c
-t
5z
-z
G)
SPACER : ~~~~
REAR CYLINDER
HALF RETAINER RING (CONVEX
SIDE FACING SPACER)
Figure 2-39
Cross Section Axial Six Cylinder Compressor
Pressure Relief Valve (except when in contact with an open flame) and non-
corrosive (except when in contac t with water). The fol-
The pressure relief valve, located on the compressor rear
lowing precautions in handling R-1 2 should be observed
head, is simply a safety valve designed to open
at all times.
automatically if the system pressure should reach a
pre-determined level high enough to cause system dam- Refrigerant drums are shipped with a heavy metal screw
age. After the pressure drops to a safe level the valve will cap. The purpose of the cap is to protect the valve and
close. After such an occurrence, the system should be safety plug from damage. It is good practice to replace the
thoroughly checked to discover and correct the ca use of cap after each use of the drum.
the abnormal pressure increase, and then should be pur- If it is ever necessary to transport or carry a drum of re-
ged, evacuated and charged. frigerant in a car, keep it in the luggage compartment.
Refrigerant should not be exposed to the radiant heat from
LUBRICATION the sun for the resulting increase in pressure may cause the
The system contains a c harge of 525 viscosity oil. R- 1 2 has safety plug to release or the drum to burst.
a definite affinity for oil, a fact which greatly simplifies the Drums should never be subjected to high temperature
lubrication of the entire system. Since the refrigerant and when adding refrigerant to the system. In some instances
the oil mix completely, even the refrigerant vapour in the
heating the drum is required to raise the pressure in the
system will carry globules of oil. As the liquid or vapour is container higher than the pressure in the system during the
circulated throughout the system it carries enough oil to operation. It would be unwise to place the drum on a gas
keep the moving parts of the system lubricated. The stove, radiator or use a blow torch while preparing for the
compressor is lubricated by the action of its own pump as charging operation, for a serious accident can result. Don 't
well as by th e oil-saturated vapour.
depend on the safety plug - many drums have burst when
the safety plug failed.
REFRIGERANT HOSES & LINES
Remember, pressure can be a powerful force . A bucket of
Special refrigerant hoses and lmes are required to carry the warm water, not over 52 deg. C, or warm wet rags around
refrigerant liquid and vapour between the various system the container is all the heat that is required.
components. These hoses are constructed with a syn th etic
material core covered by a woven fabric and coated for Do not weld or steam clean on or near the system. Welding
extra protection. These hoses are so constructed to with- or steam cleaning can result in a dangerous pressu re
stand the extreme pressures and temperatures found in the build-up in the system.
modern ref ri geration system. None but special refrigerant When filling a small drum from a large one, never fill the
type hoses should be used. drum completely. Space should always be allowed above
This system makes use of both hose c lamp fittings and the liquid for expansion. If the drum were completely full
swaged type connections (hose to metal fittings) with metal and the temperature increased, hydraulic pressure with its
to metal fittings being made using '0' rings . Care must be tremendou~ force would result.
taken when making these connections that they not be Discharging large quantities of R- 12 into a room can
turned down too tightly or damage to the '0' rings may usually be done safely as the vapour would produce no ill
result. Refer to Figs. 2-40. 2-41 and 2-42 for hose and pipe effects; however, in the event of an accidental rapid dis-
fitting detail s and torque specifications. charge of the system it is recommended that inhalation of
Flexible refrigerant hoses should not be permitted to large quantities of R-12 be avoided. This caution is
contact the hot engine manifold nor should they be bent especially important if the area conta ins a flame producing
into a radius of less than 4 times their diameter. device such as a gas heater. While R-1 2 normally is
non-poisonous, heavy concentrations of it in con tact with
a live flame will produce a toxic gas. The same gas will also
REFRIGERANT attack all bright metal surfaces.
R-12 refrigerant is used in the air conditioning system. The Protection of the eyes is of vital importance! When working
fact that R-12 has a boiling point of -30 deg. Cat sea level around an air conditioning system an accident may cause
makes it necessary to contain it under pressures ap- liquid refrigerant to hit the face. If the eyes are protected
preciably above atmospheric; this warrants special with goggles or glasses, no serious damage can result. Just
handling precautions. Also it is recommended that in the remember, any R-12 liquid that you can touch or that
event of an accidental rapid discharge of a large quantity touches you is at least 30 deg. C below zero. The eyebal ls
of R-1 2, the room be cleared of people unti l the vapour has can't take much of this temperature. If R-1 2 liquid should
dissipated. strike the eyeballs, here is what to do:
1. Keep calm.
Precautions in Handling Refrigerant-12
2. DO NOT RUB THE EYES! SPLASH THE AFFECTED
In any vocation or trade, there are established procedures AREA WITH QUANTITIES OF COLD WATER TO
and practi ces that have been developed after many years GRADUALLY GET THE TEMPERATURE ABOVE THE
of experience. In addition , occupational hazards may be FREEZING POINT. THE USE OF MINERAL, COD LIVER
present that require the observation of certain precautions, OR AN ANTISEPTIC OIL IS IMPORT ANT IN PRO-
or use of special tools and equipment. Observing the VIDING A PROTECTIVE FILM TO REDUCE THE POS-
procedures , practices and precautions of servicing re- SIBILITY OF INFECTION.
frigeration equipmen t will greatly reduce the possibiliti es of
3. As soon as possible, call or consult an eye specialist
damage to the c ustome rs' eq uipment as well as virtually
for immediate and future treatment.
eliminate th e element of hazard to the se rvi ceman.
REMEMBER- 'An ounce of prevention is worth a pound of
Refrigerant-12 is transparent and co lourl ess in both the
cure.'
gaseous and liquid state. At all normal temperatures and
pressures it will be a vapour. The vapour is heavier than air
and is non -in flammable , non-explosive, non-poisonous
0
1\)
I
1\)
~ ·~Jr:c--~~~~~ ~0=-- ~-·

0')
THER~ M O~TIC . ~-;::1 , '~"'~., ',",." , v:;-~~---~

-~::::~
FENDER SKIRT
~~~
<
. ~--~ ~T@?
m
~~
C) ,
SCREW (2 PLACES) ~ SWITCH · _.- z
~~~IAI .·
--- __- _..---:· ::j
·"~ ~-., s
----- - f ' i
~
EVAPORATOR " _ • _ i
&
~-_c
(!.-~-~~
· INLET PIPE ,
MUFFLER 0
/ ORIFICETU'E ACCEs r - -\ 1
~z
~
A T THIS FITTING
HARNESS CLI P :I
SPACER
m
SECTION C-C SCREW VIEW~ ~
z
~ THERMOSTATIC SWITCH G')
INSTALLATION DETAILS
CLIP HIGH PRESSUR E Qo
LINE TO BOD Y
;e:
:tJ
(')
0
SECTION B-B z
~ HIGH PRESSURE
c
(LIQU ID LINE ) =i
0
\\,
z-
z
G')
r
~ ~
A
~ 3,6 - 5,0 Nm CON DENSER

~ CONNECTIONS
ffi 3,1 - 4 ,1 Nm
REFRIGERATION FITTINGS ARE TO BE
&
ffi
20,0-27,0 Nm
12,0 - 18,0Nm FRONT MEMBER

ill I "''h/"'- &. LUBRICATED WITH HN -1064 IMMEDIATEL Y
PRIOR TO ASSEMBLY CONTACT WITH
OTHER LUBRI CANTS IS NOT PERMISSIBLE.
SECTION A-A PIPE MUFF LER PIPE CON IL-.- 1
Lf, 9,0 - 12,0 Nm ( 2 PLACES) TO CONDENSER TO HIGH DENSER 1.:::-
( LIOUJD P
LRES SURE '
IN E)
Figure 2-40
High Pressure (Liquid) Line Installation Details
CAUTION:
DO NOT R EMOVE SHIPP I NG PLATES OR PLUGS FROM RERIGERANT
SYSTEM UNTIL IMMEDIATE L Y BEFORE ASSEMBLY OF HOSE T O PREVENT 160, mm
ENTRY OF MOISTURE MATTER INTO SYSTEM .
REFRIGERATION HOSES & FITTINGS ARE TO BE LUBRICATE D WI T H

7;.30, m~.
r
HN -1064 IMMEDIATELY PRIOR T O ASSEMBLY CON T ACT WI TH OT HER
LUBR ICATIONS IS NOT PERM ISSILBE.
AT NO TIME IS HOSE OR END OF LOCA T ING ARM

ON CLAMP TO PROJECT BEYOND THIS BEAD ON PI PE.
;lhssE
:i
:- ..
EVAPORATOR
TO
ACC U MU L A T OR
<
m
~-0
"""'LI," z
::t
'- FLUSH TO 6 MAX
FLUSH
~ ~
s
6
-----r- ~~ , -~ ~
~~-~~MPRES S ORTO ~~~
HOSE AND C L AM P IN ST TO 3 MAX . DET
ALLATION \ ' "'- MU F FLER "
'W1iJtn A' L S
"'- ' ~z
ip• PI P~~~;~
h I~ ' '- . j'ix~~ ';-··. ~-~~ H OSE ;::::; :I:
m
--::::r~
v_
& / ~/I ACCUMULATOR

~
i --==
; :·. [:::;\_ I ~~
I /
TO
C_DMPRESSOR z
G')
L-=1 c~f;;'R 0
I / /
. CONDE CerA COMPRESSOR Qo
/
TUBE OUTLET ~/ ~
~ \\\''\\~ SPACER
' JJ
' (")
PIPE COM PRESSOR TO \ \ // Ill 0
SECTION A-A & 3,6-5,0 Nm MUFFLER HOSE COMPRESSOR TO z
2 PLAC ES
;,; 2,4 - 3,2 Nm
MUFFLER
c
L •
HOSE CLAMP ~~\ INSULATED =i

20,0 - 27,0 Nm ,----_/
NUT "'-.'h'--: 0
'
-2..~ 38,0- 44 ,0 Nm
"'-,
DASH PANEL
- \<'\
CLIP -'v AC. HOSE TO~'\-_ -zz
4 ,0-4 ,8 Nm G')
0
1\)
I
Figure 2-4 1 1\)
L6 Refrigerant Hose Installation Details ......
0
1\)
~- ~ MUS~;~E
I
1\)
.-- --------- ------------ \ FITTING INSTALLED IN
--------~~ ~ .\~------------C.- -;,_ ~ THE HORIZONTAL PLANE .
co
--~
----- ~~·~ ~--P?< C5 ~~ <
m
~~-~ ~: ~----?--~ ~-,. --~
~
----- \ \ "
.-- ~ / .-- I , ' . J "------- \ ~
ACCUMULATOR. ~
- HOSE ACCUMULATOR
TO COMPRESSOR ~
//
/ _../
~-
~--
I
I
I'
I ~
A I
I II
.....----
~~7-......,__'---....__~-. I
I
:__
/ I HOSE EVAPORATOR TO
£_ ACCUMULATOR
.---..._
~
~
.""""
"
~-
.. -
s
0
. (Pi~~-::s- ':.~~- \ ;?·~~ --: ~~~~- \:S ~
I\A ~ ~'· ~:\,~ /

/ ,_/ -..... - " -, )j ~~
1
\\i:)~
.
_
I \ / I
f\ :t:
m
~ / ~--~ ............... ~ - . ~---~'

/
~ '~t~ \\"
)Y.~~ ~ -.,_ - (YSo:: f.$.~ I~
( I
: ( ~ ......... ' I il I ---- / ~
z
CAUTION:
DDNOTREMOVESHIPPINGPLATESOR
PLUGS FROM REFRIGERANT SYSTEM
~~--·-
\\
'ELY BEFORE ASSEMBLY
EVENT ENTRY OF
!STURE AND FOREIGN MA TT ER
\
.
::--<
~~~
·,\ \
I
''
.
~'2.
, V
/
-~
._./(
__
" ' \\
-
._
~
__
,
-
'
~
y
'!'·
i.__)
f£::.
--·
1I
,- SPACER
G)
Qo
)>
:::D
0
INTO SYSTEM.
\ \
.• . '---=-- · / 0
~""""0/ . z
\ -~ ..... \
REFRIGERATION HOSES & FITT INGS ARE j \ c \ ( 1 ffi SCREW
NUT
c
TO BE LUBRICATED WITH HN-1054
IMMEDIATELY PRIOR TO ASSEMB L Y
----------- ,,
:) ·<
I I =i
CONTACT WITH OTHER LUBRICANTS \ :~ ;·n~ 1
.1
: I
. 0
-zz
ISNOTPERMISSIBLE. \ ,
, ,~\
\ • / -
'<C.-/ v
AT NO T IME IS HOSE OR END OF
LOCATING. ARM ON CLAMP TO PROJECT
BEYOND TH IS BEAD ON PIPE.
)!~ ',
/ )_,_../ \
I 't__~
'7
_
CLAMP
G)
/ ~
HOSETOCOMPRESSOR ~
- ,_...
TO MUFFLER : MUFFLER
? 7 ", .-~~ I I ~
A-A
~~NG
SE CTIO N
ffi 2,4- 3,2 Nm
'((_
& 20 - 27 Nm
ffi 38 - 44 Nm
ffi 4,0-4,8 Nm
Figure 2-42
V8 Refrigerant Hose Installation Details
~ ... . ....
SERVICE OPERATIONS
INTRODUCTION THE PRIMARY CAUSES OF SYSTEM

BEFORE ATTEMPTING ANY SERVICE OPERATION WHICH
FAILURES
INVOLVES DISCONNECTING ANY PART OF THE RE-
FRIGERANT LINE , TH E FOLLOWING PARAG RAPHS LEAKS
SHOULD BE READ AN D UNDERSTOOD. A shortage of refrigerant causes oil to be trapped in the
Air conditioning, like many other things, is fairly simple to evaporator. Oil may be lost with the refrigerant at the point
service once it is understood. However, there are certain of leakage. Both of these conditions can cause compressor
procedures, practices and precautions that should be seizure. Oil circulates in the system with the refrigerant; in
followed to prevent costly repairs, personal injury or solution wi th the liquid and in globules with the vapour. It
damage to equipment. For this reason it is strongly rec- leaves the compressor by the action of the pistons and
ommended that the information in this section be studied mixes with the refrigerant liquid in the condenser. The oil
thoroughly before attempting to service the system. then enters the evaporator and the accumulator with the
liquid refrigerant and, is returned to the compressor
MAINTAINING CHEMICAL STABILITY IN throug h th e low press ure line. Some of the oil returns as
THE REFRIGERATION SYSTEM globu les in the vapour, but more important, it is swept as
a liq uid along the wal ls of the tubing by the velocity of the
The metal internal parts of the refrigeration system and the vapour. If th e eva porator is starved, the oil cannot return
refrigerant and oil contained in the system are designed to in su fficient quantities to keep the compressor properly
remain in a state of chemical stability as long as pure R-12 lubricated.
plus refrigeration oil is used in the system. However, when
abnormal amounts of foreign materials, such as dirt, air or
moisture are allowed to enter the system, the chemical
HIGH TEMPERATURE AND PRESSURE
stability may be upset. When accelerated by heat, these
contaminants may form acids and sludge and even tually An inc rease in tem perature causes an increase in pressure.
cause the break-down of components within the system. In This accelerates chemical instability due to existing con-
addition, contaminants may affect the temperature pres- taminants in the system, and initiates chemical instability
sure relationship of R-12, resulting in improper operating in clean systems. Other results are brittle hoses, '0' ring
temperature and pressures and decreased efficiency of the gaskets, and valve diaphragms with possible decomposi-
system. tion , broken compressor discharge reed s, and se ized
compressor bearings.
The following general practices should be observed to
maintain chemical stability in the system : A fundementallaw of nature accounts for the fact that when
a substance, such as a refrigerant, is increased in tem-
Whenever it becomes necessary to disconnect a refrigerant
perature, its pressure is also increased.
or gauge line, it should be immediately capped. Capping
the tubing will also prevent dirt and foreign matter from Any chemical reactions caused by contaminants already in
entering. Tools should be kept clean and dry. This also the system are greatly accelerated as the temperature
includes the gauge set and replacement parts. When ad- inc reases. A 15 deg. C rise in temperature doubles the
ding oil, the container should be exceptionally clean and chemical action. Even in a good clean system, heat alone
dry due to the fact that the refrigeration oil in the container can start a chain of harmful chemical reactions. While
is as moisture free as is possible to make it. Therefore, it temperatu re alone can cause the synthetic rubber parts to
will quickly absorb any moisture with which it comes in become brittle and possibly to decompose, the increased
contact. For this same reason the oil container should not pressu re can cause them to rupture or blow. As the tem-
be opened until ready for use and then it should be capped perature and pressu re increase the stress and strain on the
immediately after use. comp ressor discharge reeds also increase. This can result
in broken reeds. Due to the effect of the contaminants
When it is necessary to open a system, have everything you
caused by high temperature and pressure , compressor
will need ready and handy so that as little time as possible
bearings can be caused to seize.
will be required to perform the operation . Don't leave the
system open any longer than is necessary. Finally, after the High temperature and pressure are also caused by air in
operation has been completed and the system sealed the system.
again, air and moisture should be evacuated from the
system before recharging .
In removing and replacing any part which requires un- AIR IN THE SYSTEM
sealing the refrigerant circuit , the following operations must Air res ults from a discharged system or careless servicing
be performed in the sequence shown . procedu res. This reduces system capacity and efficiency
1. Purge the system by releasing the refrigerant to the and causes oxidation of oil into gum and varnish.
atmosphere as outlined in 'Purging the System'. When a leak causes the system to become discharged, the
2. Remove and replace the defective part. resulting vacuum within the system wi ll cause air to be
3. Evacuate, leak test , charge with R-12 and performance drawn in. Air in the system is a non-condensable gas and
test the system . will build up in the condenser as it would in an air com-
pressor tank. The resultant heat produced will contribute
CAUTION: Always wear protective goggles when working to the conditions discussed previously.
on refrigeration systems. Also beware of the danger of Many systems are contaminated and also reduced in ca-
carbon monoxide fumes, avoid running the engine in closed pacity and efficiency by servicemen who either do not know
or improperly ventilated garages. or are careless regarding proper servicing procedures .
Too frequently, systems which have been open to the at- Although high temperature and dirt are re spon sibl e for
mosphere during service operations have not been prop- many difficulties in refrigerating systems, in most instances
erly purged or evacuated. Air is also introduced into the it is the presence of moisture in the system that accelerates
system by unpurged gauge and charging lines. these conditions . It can be said , therefore , that moisture is
Remember that any air in the system is too much air. the greatest enemy of all. The acids that it produces, in
combination with both the metals and the refrigerant , cause
POOR CONNECTIONS damaging corrosion . While the corrosion may not form as
rapidly with R-12 as with some other refrigerants , the
Hose clamp type fittings must be properly made. Hoses eventual formation is as damaging .
should be installed over the sealing flanges and with the
end of the hose at the stop flange . The hose should never !f the operating pressure and temperature in th e evaporator
extend beyond the stop flange . Locate the clamp properly is reduced to the freezing point, moisture in th e refrig erant
and torque as recommended . Be especially careful that the can collect at th e orifice tube and freeze . Thi s temporarily
sealing flanges are not ni cked or scored or a future leak will restricts the flow of liquid causing erratic cooling .
result. As previously mentioned , moisture in excess of th e de-
When th e compress ion fitting s are used , overtightening can siccant's capacity can cause it to powd er.
cause physical damage to the '0 ' ring gasket and will result
in leaks. The use of torque and backing wrenches is highly PRECAUTIONS IN HANDLING
recommended . When making a connection with com- REFRIGERANT LINES
pression fittings, the gaskets should always be first placed
over the tube before inserting it in the connection. All metal tubing lines should be free of kinks, beca use of
Another precaution - inspect the fitting for burrs which can the restriction that kinks will offer to the flow of refrig erant.
cut the '0 ' ring. The refrigeration capacity of the entire system can be
greatly reduced by a single kink.
RESTRICTIONS The flexible hose lines should never be bent to a radius of
Resctrictions may be due to powdered desiccant or dirt less than 4 times the diameter of the hose.
and foreign matter. This may result in starving the The flexible hose lines should never be allowed to come
evaporator and loss of cooling , or a seized compressor. within a distance of 63 mm of the exhaust manifold .
When the amount of moisture in a system sufficiently ex- Flexible hose lines should be inspected at least once a year
ceeds the capacity of the desiccant, it can break down the for leaks or brittleness. If found brittle or leaking they
desiccant and cause it to powder. The powder passes should be replaced with new lines . Use only sealed lin es
through the accumulator with the refrigerant liquid and is from parts stock.
carri ed to th e orifi ce tube screen. While some of it may pass When disconnecting any fitting in the refrig eration system ,
through the orifi ce tube into the evaporator, it may quickly the system must first be purged of all refrigerant as outlined
build up to cause a restri cti on. in this section . However, proceed very cautiously regard -
Due to the fact that suffi cient oil cann ot be returned to the less of gauge readings . Open very slowly, keeping face and
co mpresso r, it may seize . hands away so that no injury can occ ur if there happens
to be liquid refrigerant in th e lin e. If press ure is noti ced
DIRT while fitting is loosened , all ow it to bl eed off very slowly .
Dirt, which is any foreign material , may come from cleaner
residues , cutting , machining or preserving oils, metal dust CAUTION: Always wear safety goggles when opening re-
or chips, lint or dust, loose rust, brazing fluxes, paint or frigerant lines.
loose oxide scale . These can also cause seized bearings In the event any line is opened to atmosphere, it should be
by abrasion or wedging, discharge and expansion valve immediately capped to prevent entrance of moi sture and
fai lure, decomposition of refrigerant and oil , or corrosion dirt.
of metal parts. YOU SHOULD KNOW AND REMEMBER. .....
CORROSION That the inside of the refrigeration system is compl etely
sealed from the outside world , and if that seal remain s
Corrosion and its by-products can restrict valve and drier broken at any point - the system will soon be destroyed .
screen s, roughen bearing surfaces or hasten fatiguing of That complete and positive sealing of th e entire system is
discharge reeds. This can result in high temperature and vitally important and that this sealed condition is absolutely
pressure , decomposition or leaks. In any event, this means necessary to retain the chemicals and keep them in a pure
a wrecked compressor. and proper condition .
From thi s, we can see the vicious circle that can be pro - That all parts of the refrigeration system are under pressure
duced in a refrig erating system to cause its failure . Cor- at all times , whether operating or idle, and that any leakag e
rosion can be the indirect cause of leaks, and leaks can be points are continuously losing refrigerant and oil.
the direct cause of corrosion . We can also see the im -
portant role we as servicemen play in maintaining chemical That the leakage of refrigerant can be so silent that the
stability. complete charge can be lost without warning .
The maj or cause of corrosion is moi sture. That refrigerant gas is heavier than air and will rapidly drop
to the floor as it flows from a point of leakage.
MOISTURE That the pressure in the system may momentarily become
Moisture is the greatest enemy of refrigerating systems . as high as 2760 kPa and that under such press ure th e
Combined with metal , it produces oxide, Iron-Hydroxide molecules of refrigerant are forced out through th e small est
and Aliminium Hydroxide. Combined with R- 12 it produces opening or pore .
Carbonic acid, Hydrochl ori c acid , and Hydrofluoric acid . That the total refrigerant charge circulates through th e
Moisture can also cause freeze- up of powdered desi ccant . entire system at least once each minute.
That the comp resso r is co ntinuall y giving up some When conducting leak testing, the instructi ons pertaining
lubricatin g oil to the ci rc ulating refrigerant and depends to the parti cu lar type detector being used should be fol-
upon oi l in th e returning refrigerant for co ntinu ous re- lowed carefull y.
plenishment. Any stoppage or major loss of refrigerant will Refer ' Repair of Refrigerant Leaks' in thi s sec ti on for repair
therefore be fatal to the co mpresso r. details.
That th e extreme internal dryness of a properly processed
system is a trul y desert condi ti on. With th e drying material PURGING THE SYSTEM
in th e accumulator holding tightly on to th e tin y droplets of
Wh en replacing any air condi ti oning com ponent, or if th ere
resid ual moisture.
is evidence of air or other con taminati on, th e system must
That th e attraction of th e drying material for moisture is so be comp letely purged or drained of refrige rant. The pur-
powerful that if the accumulator is left open, moisture will pose is to lower the pressure ins id e th e system so that a
be drawn in from th e outside air. co mponent part can be safely removed or co ntamination
That just one drop of water added to the refrigerant will extracted.
start chemical changes that can result in co rrosion and NOTE: Alwa ys wear safety goggles when opening any re-
eventual breakdown of th e chemi ca ls in th e system. frigerant line.
Th at the sma ll est amount of air in th e refrigera tion system 1. With the engin e stopped, install the high and low
may start reacti ons th at ca n cause malfun cti ons. pressure hoses of the gauge set to th e proper hi gh and
low pressure gauge fitting s (Fig . 2-43) . The low
LEAK TESTING THE SYSTEM pressure fittin g is on th e accumulator. The high
pressure fitting is on th e compressor hose connec tor.
The comp letely assembled system sho uld be leak tested ,
preferably with an electronic leak detector, at all joints, 2. In stall purging hose to the centre port of the gauge
fittin gs, th e sigh t glass, comp ressor head, gaug e fitting s manifold to discharge th e system to a well-ventilated
and seals, whenever a leak is susp ected or as required by area (p referably out of doors). Open high pressu re
th e instructions detai led during processi ng of th e system. gauge hand va lve and discharge the vapour slowly
through the lin e at the cen tre port (Fig . 2-43) .
Leak testing shou ld be done in a place where there is
adequate ven til ati on or replacement of air to keep th e CAUTION: Do not open the valve too much or compressor
atmosphere free from R-12 and oth er contaminating va- oil may be discharged with the refrigerant.
pours.
3. When the pressu re is redu ced to be low 690 kPa on th e
At no tim e should th e leak test be performed with the high pressure gauge, open th e low pressure ga uge
engine ope ratin g or with excessive movement of air over hand valve and cont inu e discharging until all re -
the compone nts. fri gerant has been released. Close both ga uge hand
Since R-12 is heavier than air, it will be necessary to test valves.
at the lowest portion of th e fitting .
SUCTION HOSE DISCHARGE HOSE
COMPRESSOR
(TOP VIE W)
SC HRADER VALVE
ADAPTOR
SCHRADER
VALVE
LOW PRESSURE
GAUGE
_......---GAUGE
~ LINES
ACCUMULATOR
TO VENTILATED AREA.
Figure 2-43
Purging the System - Gauge Connections
If the gauge set is not available the following procedure The refrigeration system requires 294 grams of
may be used to discharge the system: 525 viscosity oil. After the system has been operated, oil
1. With ignition turned OFF and protective cap removed circulates throughout the system with the refrigerant.
from LOW-SiDE service fitti ng, discharge system by Hence while the system is running, oil is leaving the
SLOWLY connecting a gauge hose to LOW-SIDE compressor with the high pressure gas and is returning to
service fi tting on Accumulator and discharging into oil the compressor with the suction gas.
bottle (Fig. 2-44). As hose is SLOWLY tightened down NOTE: The oil level in the compressor should not be
onto schrader valve, Refrigerant-12 will begin to dis- checked as a matter of course, such as is done in the
charge from the system into the container. If no dis- engine crankcase.
charge occurs, check for missing or defective schrade~
In general, the compressor oil level should be checked only
depressor in hose fitting .
in cases where there is evidence of a major loss of system
2. With the LOW-SIDE OF SYSTEM fully discharged, oil such as:
check high-side system fitting for remaining pressure
(a) Broken hose or severe hose fitting leak.
by connecting a downward directed charging line with
straight or angle fitting adapter slowly tightened down (b) Oil sprayed in copious amounts under the hood due
to depress the valve fitting . to a badly leaking compressor shaft seal.
3. If pressure is found on the high-side of the system, (c) Collision damage to refrigeration system components.
attempt to discharge high-side using same procedure However, some oil is lost when air conditioning system
as used for low-side. (Th is con diti on indicates a re- components are replaced.
stric tion and hi gh-side components shou ld be re- 1. If there are no signs of excessive oil leakage, add the
moved and/or diagnosed to determine the area following amounts of oil depending on part replaced:
res tricted.) Evaporator ................ .. ............................... ...... 85 grams
Even after discharging is completed , proceed very cau- Condenser ..... .................. ......... ... ......... ..................... .. 57 grams
tiously when removing regfrigerant lines. Open fittings very
Accumulator ..... Drain oil, measure, replace same amount
slowly, keeping face and hands away so that no injury can
plus 28 grams See Item 2 below.
occur if there happens to be liquid refrigerant in the line.
If the pressure is noticed when a fitting is loosened , allow 2. On the CCOT system, if EITHER the accumulator or the
it to bleed off very slowly. compressor is to be replaced, or if there are signs of
4. When the system is completely discharged (no vapour excessive oil leakage, then BOTH accumulator and
escaping with hose fu lly-ti ghtened down), measure, compressor must be removed. Drain oil and measure
record and discard any col lected oil. If this quantity is to determine correct quantity of oil replacement for the
more than 15 grams it must be added to system, plus system. If the amount of oil recovered is 11 0 grams or
any trapped in removed parts before Evacuating and more, replace with a like amount of new oil. If less than
Charging with Refrigerant-12 . 11 0 grams are recovered , add 1 70 grams of new oil.
NOTE: A good system will have 170 grams of oil found in
the accumulator and /o r compressor. Neither necessarily
USE VALVE ADAPTER has 85 grams, could be more or less. This is why BOTH
have to be measured.
GAUGE HOSE In addition to these measured amounts, an additional
28 grams MUST be added to replace that amount captured
in the old desiccant of the replaced accumulator assembly .
O I L BOTT L E Neg lect any fluid oil coating loss in case of line change.
UNCAPPED TO
3. Install compressor and system components.
A L LOW GAS
4. Evacuate, charge and leak test system.
T O ESCA PE
EVACUATING AND CHARGING THE

SYSTEM
OI L
In all evacuating procedures detailed in the following text ,
the specification of 711 mm of Mercury vacuum is used.
This figure is only obtainable at or near sea level elevation.
For each 300 m, above sea level where this operation is
being performed, the specification should be lowered by
Figure 2-44 25 mm .
Alternative Method of Discharging System E.g. At 1500 m elevation, only 584 mm Hg can nor-
mally be obtained.
The following procedures are described using the portable
CHECKING COMPRESSOR OIL LEVEL AND evacuating and charging equipment. As a safety precaution
it is recommended that goggles be worn during processing
ADDING OIL operations.
NOTE: Smal l amo unts of oi l lost d uring servicing can be
replaced by removi ng the co mpressor suction hose at the PRELIMINARY OPERATIONS
accum ula tor out let connecto r; pou r th e correct quantity of 1. Ensure that the vehicle is in 'Park ' for automatic or
refrigerant oil into the hose and then reconnect the hose neutral for manual transmission vehicles with parking
to the accumu lator. brake on.
2. In orde r to charge th e system qui ckly, it is recom- CAUTION: Do not operate the system with this small re-
mended that the vehic le should be at rest for a period frige rant charge.
of approximate ly 4 hours to reac h ambient tempera- Perform leak test as outlined under heading 'Leak Test ing
ture before cha rging. th e System', and correct the condition causing the leak.
Re-evacuate for 20 minutes to 711 mm Hg or bette r and
EVACUATION EQUIPMENT CHECK c lose both vacuum pump valves.
Before proceeding with system processing , c hec k th e 5. If 71 1 mm of vacuum is confirmed for 3 minutes as in
condi tion of the evacuation eq uipm ent as follows :- item 3 then proceed with the leak test and purge.
Ensure gauge manifold valves do not lea k and th at hoses
and neoprene washe rs are sound, also th at th e c hargin g
cylinde r hand valve does not leak. LEAK TEST AND PURGE
Where the co ndition of the equi pm ent is not kn own , test th e Even if the system is capable of sustaining a vacuum of
vacuum pump and connec ti ons as foll ows:- Co nn ect th e 711 mm after evacuation , it is still possible that a minute
equipmen t as ou tlin ed in Fig . 2-45 , ' Evac uation and leak which co uld result in refrigerant loss may still be
Charging Line Connections', with th e excepti on of th e present.
connec ti ons at the ga uge fittings. Open both manifold hand Th erefore, it is necessary that a leak test be carried out.
valves and ensure th e cha rging cylinder va lve is closed. Admit a 340 grams cha rge of R-12 into the system and
The hoses which normall y co nnect to the gaug e fittin gs leak te st as outl ined und er heading 'Leak Testing the
should be plugged with co unterbored 1 I 4 in . flare plug s. System '.
Start the vacuum pump.
A vacuum of not less than 711 mm Hg should be pulled on CAUTION: Do not operate the system with this small re-
the connecting equipment and there shoul d be no ap- frigera nt charge.
preciable rise over a 3 minute interval after the vac uum After leak testin g has been carried out, the test charge
pump is stop ped wi th both pump hand valves closed . should be purged to the ou tside atmosphere (with the
vac uum pump running) through the purging hose con-
EVACUATION AND CHARGING LINE nected to the vacuum pump discharge connection. This is
CONNECTIONS important in th e rem ova l of any contaminants which may
1. DO NOT CON NECT THE HI GH PRESSURE LINE TO still be present in the system.
THE AIR CONDITIO NIN G SYSTEM!!
2. KEEP THE HIGH PRESSURE VALVE ON THE
CHARG ING STATION CLOSED AT ALL TI MES!! FINAL EVACUATION
3. PERFORM THE ENTIRE EVACUATE AND CHA RGE Aft er the system has had the initial evacuation, leak test
PROCEDURE THROUGH THE ACCUMULATOR and purge , th e final evacuation should be carried out in a
LOW-SIDE PRESSURE SERVICE FITTING. similar manner to the initial evacuation for a further
4. Following these procedures will prevent acciden tal 15 minute period .
high-side vehicle system pressure being subj ected to
the Charging Station in the even t an error is mad e in
valve seq uence during compressor ope rati on to pu ll in
FINAL CHARGE
the Refrigerant-1 2 charge. Close vacuum pump sucti on valve and switch off vacuum
pump .
NOTE : Ensure that th e charging cy lind er has suffi c ient
refrigerant to leak test and recharge th e system; 2 kg is th e Open c harging cylinder delivery valve to low-side pressure
minimum requirement. se rvi ce fitting and release 1.2 kg of R-12 into air con-
ditioning system. (Add 60 grams extra for refrigerant lines).
If th e spec ified amount of R-1 2 does not flow into system
use th e co mpresso r as follows to draw in the remainder of
th e c harge.
INITIAL EVACUATION AN D LEAK TEST
1. Connect the purging hose to the vac uum pump dis- NOTE : Keep high pressure valve on charging station closed
charge connec tion . at all times during this operation.
2. With gauge manifold valves and vacuum pump dis- 1. Shut. off R-12 delivery valve.
charge valve open, but with charg in g cylind er and 2. Bypass the CCOT system thermo s!atic switch be re-
vac uum pump suction valves c losed, start th e vacu um mov in g co nnector from switch and installing jumper in
pump - open the vacuum pump suction valve slowly co nnector to keep compressor switch from cycling.
and evacuate system for 20 minutes. Close bo th 3. Start engine , run with choke open and fast idle speed
vacuum pump valves . reduced to norm al idle, set Air Conditioning Mode
3. Check vacuum to be 711 mm Hg or better for control on maximum cold and blower speed on Hi.
3 minutes. 4. SLOWLY re-open R-1 2 source valve and contro l to
4. If 711 mm or better was obtained on the evac uati on maintain 40 psi or less LOW-S IDE gauge reading to
equipment check, but not on system evacuation, th en draw in balance of requ ired full-charge amount of
the system has a leak which must be located and R-12.
repaired. NOTE: Thi s operation can be sped up by placing a large
The folio 'ng procedure should be adopled: 'ilh 'Oih volume fan to pass air over /he condenser. Jl condenser
vacu um pump valves closed locate the cha rging cyl ind er temperature is maintained below cha rging cylinder tem -
to permit 340 grams weight of R-12 to ente r system by perature, refrigerant will en ter system more rapidly.
gently opening cylinder hand va lve. Close th e valve when 5. Shut off R-1 2 so urce valve and run engine for
the recommended charge has been admitted. 30 seco nd s to c lear lines and gauges.
6. With th e engine runnin g, remove th e c hargin g low-side has been involved in a co lli sion . If th e system has been
hose adapter from the accumulator service fitting. opened as th e result of a co lli sion, it will permit th e entry
Un sc rew rapid ly to avoid excess R-1 2 escape from of air, moistu re and dirt that will ca use intern al damage. As
system. th e length of time the system has been open and th e exten t
WARNING : NEVER REMOVE A GAUGE LINE FROM ITS of damage to the components will gove rn th e rep lacement
ADAPTER WHEN LINE IS CONNECTED TO AIR CON- of parts and the service operati ons required , a definit e
DITIONING SYSTEM. ALWAYS REMOVE THE LINE AD- procedu re cann ot be rec ommend ed to cove r all cases. Th e
APTOR FROM THE SERVICE FITTING TO DISCONNECT A fo ll owing, however, may be used as a guid e:
LINE. DO NOT REMOVE CHARGING HOSE AT GAUGE SET 1. Make ce rtain th e co mpresso r clutc h is disengaged if
WHILE ATTACHED TO ACCUM ULATOR. THIS WILL RE- th e ca r is to be operated before repa irs are made .
SULT IN COMPLETE DISCHARGE OF SYSTEM DUE TO 2. In spect all units and lines, noting any damage.
THE DEPRESSED SCHRADER VALVE IN SERVICE (a) If co nd ense r is damaged, it shoul d be repl aced .
LOW-SI DE FITTING. No repairs such as solde rin g, brazing or welding
7. Replace protective cap on Acc umul ator fitting and sho ul d be attempted .
remove jumper wire from thermostatic switch. Re- (b) Replace accumulator if system was open for any
connect thermostatic switch . period of tim e.
8. Leak check system with Leak Detector. 3. Check co mpresso r and cl utch pulley for c racks . If
9. With system fully charged and leak-c hec ked, co ntinu e co mpressor does not show ev id ence of extern al
to ope rate system and test for proper system pressures da mage, it may be used .
as outlin ed under PERFORMAN CE TEST.
COMPONENT PART REPLACEMENT AND Foreign Material In The System

ADJUSTMENT Whenever moisture or oth er foreign material is found in th e
system , it mu st be removed by flu shin g th e individual
co mponents before res toring th e system to operati on .
PREPARING SYSTEM FOR REP LACEMENT OF
COMPONENT PARTS In the case of compresso r mec hani ca l failure, perform th e
foll owin g ope rations:
Air co nditi ong, like many oth er thing s, is fairly simpl e to
servi ce once it is understood. Howeve r, th ere are ce rtain 1. Remove co mpresso r and forwa rd to agent for ove r-
haul .
procedures, practi ces and precautions that should be
followed. For this reason it is strong ly reco mm end ed that 2. Rem ove the accumulator , discard th e unit and repl ace
the preceding information in thi s sec ti on be studi ed th o- with new assembly.
rough ly before attempting to se rvice th e system . 3. Remove expansion tub e and clean filt er.
Great emphasis must be placed upon ke epin g th e system Th e co nden se r and evaporator assemblies ca n be flu shed
clean. Use plugs or caps to close system components and in th eir installed pos iti on howeve r they must be discon-
hoses when th ey are opened to th e atm os phere. Kee p your nec ted from their hoses and / or conn ecting lin es and
work area c lean. flushed individually
WARNING : ALWAYS WEAR PROTECTIVE GOGGLES Th e graduated chargi ng cyli nd er with a full 2 kg of re-
WHEN WORKING ON REFRIGERATION SYSTEMS. GOG- frig era nt c harge should be used for th e flu shin g and
GLES ARE INCLUDED IN MOST SETS OF AIR CON- subsequent processing operati ons and a fl ex ib le c hargin g
DITIONING SPECIAL TOOLS. ALSO , BEWARE OF THE hose shoul d be used to pe rfo rm the flushin g opera tion . Th e
DANGER OF CARBON MONOXIDE FUMES BY AVOIDING c harging hose shoul d be connec ted to eac h co mponent in
RUNNING THE ENGINE IN CLOSED OR IMPROPERLY turn using suitabl e unions, fabrica ted length s of copper
VENTILATED GARAGES. tu be and salvaged lengths of refrigeration hose. All com -
In removing and repla ci ng any part whic h requires un- pon ents and lines should be flushed in th e normal direction
sealing the refrige rant c irc uit the followin g operati ons, of refrige ran t fl ow with liquid R- 12. Co nn ect th e charging
whi ch are described in thi s section, must be perf ormed in cy linder to the co mpon ent inlet using th e chargi ng hose
th e sequ ence shown. and suitabl e co nnecti ons. Bl ock the outlet end of th e
co mponent and charge to cylind er press ure by openin g th e
1. Purge the system as outlin ed earlier.
cy lind er hand valve. Wh en refrige rant fl ow ceases , close
2. Remove and replace th e defec tive part. hand valve, allow to stand for several minutes and unplug
3. Evacuate, charge and check th e system. outl et end of co mponent.
Refrigeration System Open To Atmosphere CAUTION: It is possible that liquid refrigerant and/ or metal
Broken tubes or units will allow air, moisture and dirt to chips may be ejected when the plug is removed, th erefore,
enter; th ese parts should be sealed as soon as possible it is mandatory that sa fety goggles and gloves be worn
until such tim e as they are rep laced . during flushing operations.
If the system is open for more th an 30 minutes (dependin g
on humidity), th e desiccant in th e accumulator will abso rb Wh en flu shin g is co mpl eted proceed as follows:
an excessive amount of mo istu re and th e accumulator must 1. In stall th e ex pan sio n tube.
be replaced. 2. In stall a new accumulator.
3. In stall the replac emen t compresso r (refer 'Compressor
Collision Service Se rvice ').
It is ve ry important that th e air co nditi onin g system be 4. Evac uate, leak test, charge and performance test th e
in spected as soo n as possible whenever a car so eq uipped system
SUCT ION HOSE D ISCHA RGE HOSE
COM PR ESS OR
(TOP VIEW)
SCHRADER V ALVE
A DAPTOR
SCHRADER
VA L VE
LOW PRE SS URE:
GAUGE
<
m
z
~
GAUGE LINEPLUGGED
s
6
ACCUMULATOR
~
:I:
m
~
VACU U M CON T ROL VALVE
CYLINDER
FILL VALVE z
G')
------!'--BLEED VALVE
Qo
):>
REFR IGERANT
CYLINDER
::c
VACUUM PUMP (")
0
z
c
=i
CHA RGING CYLINDER
6
-zz
G')
0
1\,)
I
Figure 2-45 w
Evacuation and Charging Line Connections 01
REFRIGERANT LINE CONNECTIONS permanent set around the sealing beads of the connecting
pipes and it is necessary to cut the hose to enable it to be
'0' Rings removed . Use only approved refrigeration hose. Never use
Always replace the '0 ' ring when a connection has been heater hose. Use extreme care not to nick or score the
broken. When replacing the '0 ' ring , first dip it in clean sealing beads when cutting of the hose, cutting the hose
refrigeration oil. Always use a backing wrench on '0' ring lengthwi se increases the possibility of th e tube sealing
fittings to prevent the pipe from twisting and damaging the bead damage.
'0' ring. Do not overtig hten. Refer Figs. 2-40, 2-4 1 and
2-42 for installation details and torque recommendations .
REP AIR OF REFRIGERANT LEAKS
Hose Clamps
Any refrigerant leaks found in the system should be re -
When hose clamp connections are encountered, special paired in the following manner.
procedures are necessary for both installation and removal.
For installation, proceed as follows: Leaks at '0 ' Ring Connections
1. Coat tube and hose with clean refrigeration oil. 1. Check the torque on the fitting and, if too loose tighten
2. Install clamps on hose, hooking the locating arms over to proper torque. Always use a backing wrench to
the cut end of the hose (Fig. 2-46). prevent twisting and damage to the '0' ring . Do not
overtighten. Again leak test the joint.
3. Carefully insert hose over the three beads on the fitting
and down as far as the fourth, or locating bead. Hose 2. If the leak is still present, discharge the refrigerant from
must be 6.35 mm to fi"ush against this fourth bead . the system as described under ' Purging the System'.
3. Inspect the '0 ' ring and the fitting and replace if
CAUTION: Use no sealer of any kind. damaged in any way. Coat the new '0' ring with clean
4. Tighten the hose clamp screw to 4.0-4.7 Nm , torqu e. refrigeration oil and install carefully.
DO NOT RETOROUE. The clamp sc rew torqu e will 4. Retorqu e the fitting , using a backing wrench and then
normally decrease as the hose co nform s to th e force add 340 grams of R-12 to the system and rech eck for
of the clamp. The screw shou ld be re torq ued on ly if its leaks.
torque falls below 1.12 Nm. In this case, retorque to
2.25-2.93 Nm further tighten ing may damage the CAUTION: Do not opera te the system with this small re-
hose. frigerant charge.
When removing a refrigerant hose, with hose c lamp con- 5. Purge the system , thus removing the R- 12 in stal led.
nections , with a sha rp knife, carefully, make an angle c ut 6. Evacuate and charge the system.
in the hose as shown in Fig. 2-46. This shou ld loosen th e
hose so that it may be worked off the fitting . Leaks at Hose Clamp Connections
NOTE: If it is necessary to disconnect a refrigerant hose 1. Check the tightness of the clamp itself and retorque if
with hose clamp co nnections for any reason, the hose mu st necessary. Recheck for leak.
be replaced . This is because the inside of the hose takes 2. If leak has not been corrected, purge the system,
loosen clamp and remove hose from co nnection. In -
spect condition of connector. Replace scored or
dam aged parts.
MAKE ANGULAR CUT FOR
HOSE REMOVAL 3. Dip end of new hose in clean refrigeration oil and
carefully reinstall over connector. Never push end of
hose beyond the locating bead . Properly torqu e the
clamp.
4. Recheck the system for leaks by installing 340 grams
of R- 12 into the system. Do not run comp resso r.
5. Purge the system, thus removing the R-1 2 installed .
HOSE CLAMP
6. Evac uate and cha rge the system .
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell , a repl acement compressor should be fitted. Refer
'Co mpresso r Service' .
Refrigerant Hose Leaks

After a leak or rupture has occurred in a refrigerant hose,
HOSE CLAMP
;;;;.11~G B:;z or if a fittin g has loosened and caused a considerabl e loss

of refrigerant and oil , th e entire system shou ld be flushed
and rec harg ed with oi l after repairs have been made. If the
system has been open to atmosphere for any prolonged
·,._~~ period of time th e accumulator should be replaced.
~
SEA LING BEADS
COMPRESSOR SERVICE
In fo rm ation concerning approved compressor servicing
Figure 2-46 agen ts is availab le from the nearest GMH Vehicle Service
Hose Clamp Connections Depa rtment situated in each mainland cap itol ci ty .
False Compressor Seizure Compressor Failure

Slipping or broken air conditioning drive belts and/or If the compressor has failed mechanically to the extent th at
scored clutch surfaces may be experienced on initial start metal chips and shavings are found in the oil or if th ere is
up of an air conditioning compressor after an extended any evidence of moisture, dirt or othe r foreign matter, it is
period of storage or non-operation of the compressor. This recommended that the entire system should be flushed
would indicate a seized compressor; however, an overhaul with liquid R-12 and the accum ulator be rep laced as
or replacement of the compressor may not be necessary. outlined in 'Foreign Material in the System' .
During extended periods of non-operation, changes in
temperature cause the refrigerant in the air conditioning Compressor Removal
compressor to expand and contract. During this movement, (For details of installation of components refer Figs. 2-4 7
lubricating oil carried by the refrigerant tends to migrate and 2-48).
from highly polished surfaces in the compressor such as 1. Purge the refrigerant from the system .
the ball seats and wobble plate. Without lubricating oil at 2. Remove the compressor connector attaching bolt and
these polished surfaces, they 'wring' together and appear
connector. Seal connector outlets.
to be seized.
3. Disconnect electrical lead to clutch actuating coil.
Before the time and expense of an overhaul is invested, use
4. Loosen pivot bolts and detach belt.
the following check to determine if the comp ressor is
actually seized. Remove the compressor drive belt. With a 5. Remove the nuts and bolts attaching the compressor
wrench on the compressor shaft lock nut or Spa nner to its mounting (Figs . 2-4 7 and 2-48).
Wrench J-9403 on the clutch drive plate , 'rock' the sha ft 6. Drain and meas ure oil in the compressor. Check for
in the opposite direction of normal rotation. After the evidence of contamination to determine if remainder
compressor is broken loose, 'rock' the shaft back and forth. of system requires servicing.
This should be sufficient to return lubricating o il to the
'wrung ' surfaces and allow the compressor shaft to be Compressor Installation
turned by hand . Once the compressor turns freely , rotate 1. If oil previously drained from the compressor upon
the comp re ssor at least three complete turns. Start the removal shows no evidence of contamination, place
engine and operate the compressor for a minimum of one the recommended amount of fre sh refrigeration oil into
minute. the compressor before installation. If it was necessary
This procedure will not affect a compressor that is actually to service the entire system because of excessive
seized but shou ld be attempted before overhauling a contamination in the oil removed , install the entire
compresso r known to have been idle for a month or longer. 284 g rams charge of fresh refrigeration oil in the
compressor. (See 'C hecking Compressor Oil Level and
Adding Oil' in this section).
Compressor Replacement 2. Position comp ressor on the mounting brackets and
IMPORTANT: If it is found necessary to replace a com- install all nuts, bolts and lock washers (F igs. 2-4 7 and
pressor, the Dealer sho uld order a replacement and await 2-48).
the arrival of the replacem ent before removing the de- 3. Install the connector assembly to the compressor rear
fective unit, so that the system can be kept sealed. head , using new '0' rings. Tighten bolt to 24-33 Nm
Replacement compressors as supplied will contain the full torque.
284 gram charge of 525 viscosity refrigeration oil. How- 4. Connect the electrical lead to th e coi l and install and
ever, since some oil will remain in the system when the adjust compressor drive belt .
faulty compressor is removed it will not be necessary to 5. Evacuate , leak test and charge the system .
admit the full replacement compressor charge, unless 6. Carry ou t performance test.
action as indicated under ' Foreign Material in the System '
is warranted when it will be necessary to admit the full Compressor Drive Belt Tension Adjustment
284 grams oil charge.
Adjust the compressor drive belt, using Belt Tension Dial
Before removing the compressor proceed as follows: Gauge 982350 (Superseded No.8620B).
1. Run the system for 1 0 minutes at engine idle speed NOTE: At the time of initial installation of a new belt only,
with controls set for maximum cooling and high blower th e strand tension should be 140 plus or minus 5 but after
speed, except where it is impossible or impracticable 1 0 minutes 'run-in ' or with used belts, a value of 95 plus
to do so. or minus 5 applies.
2. Turn off the engine, purge the system, remove com-
pressor from vehicle, place it in a horizontal position
with the drain plug downward. Remove the drain plug
and , tipping the compressor back and forth and
Compressor - Partial Removal and Installation
rotating the compressor shaft, drain the oil into a clean
con tain er, measure and discard the oil. Record th e In order to perform certain engine operations, it is
amount of oil removed from the faulty compressor. necessary to move the compressor ou t of the way. Thi s can
Drain all the oil from the replacement compressor and be done without discharging the refrigeration system as
replace only the amount speci fied in 'C hecking foll ows:
Compressor Oil Level and Adding Oil' in this section.
Removal
NOTE: When adding oil to the compressor it will be
necessary to tilt the rear end of the compressor up so that 1. Perform steps 3 thru 5 of compressor removal above.
th e o il will not run out of the suction and discharge ports. 2. Move complete assembly c lear of work area, being
Do not stand the compressor on the drive pulley end, as the careful not to kink hoses. Use rope or wire to hold
shaft may be moved in respect to the Wobble Plate. co mpressor out of way.
0
1\)
I
w
(X)
& 24 - 32 Nm.
<
&. BO LT A:, m
SPACER
f 12 - 16Nm.
z
I
:::1
&
s
75-100Nm .
d:, 20 - 27 Nm.
&
r
34 - 46Nm.
GENERATOR
0
-~-: SUPPORT - COMPRESSOR & GENERATOR ~
Lt_ BOLT 1
L......-~ vr
-:--~ "--, ~
ENGINE
MOUNTING
BRACKET r SH IMS
:I
m
~
~ill F.-.
z
C)
BOLT ~L..J..::,.BOLT
2P LACES ~ Qo
~0 ~
COMPR ESSOR REAR
;:;...
MOUNT ING BR ACKET ~
r f..f..:!. :c
~
BOLT
2 PLACES (")
DETAILS O F DRIVE BELT LAYOUT 0
r.01V1 PRESSOR z
CON NECTOR
VIE W[B] c
SEE APPROPRIATE SECT ION OF -4
MANUAL FOR INSTRUCTION
0
BELT TENSI ON
z
z
~
~
'
C)
<~;,~ ~
~ GASKETS
,c . ti#'
:-C
. -~
L COM PR ESSOR COMPRESSOR lJJ
GROUND W IRE //
DISPOSE OF SHIPPING PLATE & LOCKWASHER . < oR VACUUM TAKE -C FF

RE T A IN ' 0' RING GASKET AND LUBRICATE WITH FITTINGS
HN1064 IMMEDIATELY PRIOR TO ASSE M BL Y .
CON T ACT WITH OTHER LUBRICANTS IS NOT
PERMISSIBLE. VIEW [ g
Figure 2-47
L6 Compressor Installation
GASKE TS
I
' ~@rg ~/
.~
/1'__. BOLT ----- r ; .0-c/~ j
BOLT
/ -: (J
COMPRESSOR 6
( COMPRESSOR REAR MOUN TI NG
CONNECTOR \ BOLT
I
BRACKET
O(y N!.._.~~
~
///
/ / SHIM
USE ONLY WHEN REQUIRED
&
~ '---~
~@
BOLT
~ ~/ l -------
~ --- ~SPACER <
~~,_/
REAR -
m
~J' - ~'~
:.
~~~~~E~ssf --- ~
- ~ ~- ~ -SPACER SHIM , .. . _ .,.
', ,_,, z
REQUIRED
_ /~.. ' . ~-/cf"" /;_-::~ ~- '! :j
~f\G ~~~~
7~./;;- C;l'
-<'"3 ~' '".
~
USE AMOUNT
C ."\ I 'Y:.r. I ' I
c
E
c!:::zj
~ _;·.~
(t':.
, >J
! ~~,
-----=---: -.
~~
EX T ERNAL
TOO T H LOCK /
ASHER
D: o
~I);L '---'> - - £~ V~~r'
lv'.:;
BOLT '--'-- .
d . ;/
"-
i' _, · '
'
_,' : ·
.. ' -
J.9,Jr -.o' ;, 0
~" ../,/
~,~--/
- W
~
"~-
'
~ ;:
ffi NUT !
& 3 PLACES ' I
-~' \
((./@'
~~- ' I
'/ / /'
j // /~
\ ~z
.if-- . ·
I I
I I - '' I
-~v _, / - 1 1 . .1
I :I:
~>-~ ---{ t/., y/// I
m
~
'-. ~ •i
i
~/
/ I ~
·~ I --.... ___/
I
zG')
q: --!1 ~ COMPRESSOR DR I VE BELT
~&@ -, Qo
RE AR BRACE TO FRO NT FOR BELTS REF . APRROPRI ATE SECTION
ENGINE MOUN T / OF MANUAL
~
~
r',,
....... -~) "'.,... j,
* DISPOSE OF SHIPPING PLATE & LOCKWASHER .
RETA IN ' 0 ' RING GASKET AMD LUBR I CATE WITH :::D
HN 1064 IMMED IATELY PRI OR TO ASSY . CONTACT
'C'->-
'N ITH OTHER LUBRICANTS IS NOT PERMISSIBLE . n
------- ' "{v Botf ;j 0
~ z
12 -16 Nm. THREE
c
& 24 -32 Nm I
~
PLACES
=i
Lt .36-50 Nm. I CAUTION : 0
& 34 - 44 N m. COMPRESSOR DO NOT REMOVE SH IPP ING PLATES AND / OR PLUGS FR OM
z
Lt 20-28 N m
REFRIGENT SYSTEM UNTIL IMMEDIATELY BEFORE ASM
OF HOSES . TO PREVENT ENTR Y OF MOISTUR E OF FOREIG N -z
G')
& 14- / 9 Nm
~ ATTERINTOSYSTE M .
0
1\)
I
Figure 2-48
w
(0
V8 Compressor Installation
0
1\)
I
~
0
<
m
I §
"~I E
-~ ~. 7((-:\~~-r~~ 6
~
,",~-~~\ ~
:I:
m
~
', ~ ~\\ /
" ~ z
C)
'\~ ~ 4 QO
~-JW&.·/ -- -- - ::D
n
FOR CONTINU~T ION
O FPIPESREFE
':i/X~ /~". •_, /
~~~\
-~~,~~. ~-~
/;:)
---- -
~
0
z
c
-4
'>('\,_' ./ / 6z
z-
f ~~-~~~------~-r--7
FIG 2 - 40
~-
· "'
~~~
k"' I
C)
1.\
ffi
/
BOLT _} FO -----~
UROFF
~ -- ~ .
-- -
.
/
,,
CROSSMEMBER
_/ /r-- ~~~
& 3,6 - 4,6 Nm
Figure 2-49
Condenser Installation
VENTILATION, HEATING & AIR CONDITIONING 02-4 1
Installation Removal
1. Perform steps 2 and 4 of compressor installation 1. Discharge system of refrigerant. Refer 'Purg ing th e
above. System' in this section .
2. Check system operation to assure that no refrigerant 2. Disconnect accumulator inlet and outl et connec ti ons.
was lost and system performs normally. Cap or plug open lines immediately.
3. Remove accumulator attaching screws and remove
CONDENSER accumulator.
No repairs, such as welding or brazing, should be at- 4. Check amount and condition of oil in accum ulator.
tempted on the condenser because of its construction. If
the vapour passages in the horizontal tubes or return bends Installation
or manifolds have been damaged in any way, the con-
Installation is reverse to the removal procedure taking care
denser should be replaced with a new one.
to note the following:-
Removal 1. Place the correct quantity of clean new 525 vi scosity
refrigerant oil in accumulator (28 grams) . Refer
(For details of installation of components refer Fig. 2-49) 'Checking Compressor Oil Level and Adding Oil ' in this
1. Purge refrigerant from system. section.
2. Remove the fan shroud and fan. 2. Use new '0' rings on connections and lubricate them
3. Remove the radiator. Refer to Engine Cooling Section with clean 525 viscosity refrigerant oil .
for radiator, fan and fan shroud removal. 3. Evacuate and re-charge system after checki ng for
4. Disconnect inlet and outlet tubes from the condenser leaks.
at the compression fittings. Loosen nuts carefully since
there may be liquid refrigerant i11 the condenser. Cap
or tape inlet and outlet tubes immediately. THERMOSTATIC SWITCH
5. Remove the four condenser mounting bolts and lift
condenser from its location. Removal
1. Remove electrical connectors to the switch.
Installation
2. Remove screws holding switch body to blower casing.
Reverse to the removal procedures: (Refer Fig. 2-49).
3. A capillary line (small tube) extends from the switch
When installing the new assembly note the following: with the other end attached to the evaporator inlet pipe
1. Add 57 grams of refrigerant oil to condenser. (12.7 mm 0.0.) with two clamps. This end is covered
2. Use new '0' ring seals coated with clean refrigeration with insulation material. Carefully remove the insula-
oil when making inlet and outlet tube connections. tion and loosen clamps enough to pull the formed end
of the capillary tube out from under the clamps .
3. Leave final tightening of tube connections until con-
denser is finally installed. 4. Identify capillary tube location area by marking th e
inlet pipe where the capillary tube is mounted. Solvent
4. Evacuate, leak test, charge and performance test the
clean pipe area to remove remaining insulation ma-
system. terial and dirt.
Installation
1. Mount switch body to blower housing in previous
ACCUMULATOR ASSEMBLY location . Torq ue screws to 1.7 to 2.2 Nm . Do not
overtorque as this could distort switch body and affect
The accumulator assembly for the CCOT system has the swi tch cal ibrati on.
desiccant sealed within the can. It is not serv iced separ··
2. Mount formed end of capillary tube to inlet pipe in
ately. For this reason it is imperative to keep the system and
SA ME POSITION AS THE ORIGINAL tube. Do not in-
the can sealed at all times .
stall new tube more than 12.7 mm in either direction
The sealing plugs on any replacement assembly should of previously marked location .
only be removed immediately prior to refrigerant lines 3. Adjust each clamp before tightening so that width of
being connected. clamp covers the capillary tubes formed end. Tighten
If the refrigerant lines are left open for longer than screws to 1.7 to 2.2 Nm do not overtorque.
30 minutes the accumulator must be replaced. It should 4. Recover tube and pipe with insulation material. If or-
also be replaced when: iginal insulation material is damaged, replace with
1. A physical perforation to the accumulator is found, same type material (available from G MP&A).
resutling in a leak. 5. Reconnect terminals and test switch operation.
2. The expansion tube (orifice) screen is plugged.
3. The compressor inlet screen is plugged.
4. An evaporator fails because of inside-out (internal) BLOWER ASSEMBLY
corrosion.
DO NOT replace the accumulator assembly when: Removal
1. Merely a dent is found in the outer shell of the ac- 1. Disconnect battery ea rth lead .
cumulator. 2. Disconnect electrical connections to thermostatic
2. A vehicle is involved in a collision, the refrigerant lines switch and blower resistor.
remain intact and no physical perforation to the ac- 3. Remove screws holding thermo static switch body to
cum ulator is found. blowe r casing.
4. Disconnect blower motor electrical connections. 4. Remove blower asse mbly.

5. Remove the plenum chamber water deflector and 5. Discon nect th e evapo rator refr igerant line co nn ections
engine com partment seal (refer Fig. 2-50). and cap or plug both the lin es and the eva porator
6. Remove th e three nu ts sec uring the blower assembly connectio ns.
to th e dash panel and evaporator housing. Also re- 6. Drain coo ling system suffi ciently to disco nn ec t heater
move th e two bol ts holding the blower housing to the hoses from heater co re co nn ections.
plen um chamber.
CAUTION: The hea ter can easily be damaged in th e area
Installation of the core tube attachmen t seams, whenever undue force
Repl acement is reverse to removal operations taking ca re is exerted on them. When th e hea ter hoses do not readily
to note the fo llowing: come off the tubes, the hoses should be cut just forward
of the core tubes. The portion of th e hose remaining on th e
1. Take care to prevent damage to the capi llary tube
tube should then be split longitudinally. Once th e hoses
when installing blower assembly and thermostatic
have been split they can be removed from th e tub es without
switch.
causing damage to the core.
2. Ensure correct location of seals and sealing materials
7. Remove instrument panel lower tri ms (refer body trim
at joining faces before tighten ing attach in g parts.
section).
8. Remove steering col umn lower cove r (refer stee rin g
section of this manu al).
AIR INLET ASSEMBLY 9. Remove transm iss ion co nso le (refer body trim sec-
ti on).
Removal 1 0. Remove in strument panel left sid e lower panel and
1. Di sco nn ect battery negative lead. glove co mpartm ent (refer body trim section).
2. Remove ai r conditi oning centre outlet and auxil ary 11 . Rem ove left and right outboard vent ducts.
switch pan el. Th ere are retainin g sc rews behin d th e 12. Remove two sc rews retaining lower level outl et and
end swi tches. (Refer Fig. 2-50) remove outl et.
3. Remove instrum ent clu ster (refer to ap propriate 13. Remove th e two sc rews in switch aperture numbers 1
electri cal secti on of th is manu al). and 5 and remove centre vent and ce ntre vent du elin g.
4. Partial ly di smantl e demi si ducts from th e upper outl ets 14. Disconn ect heater doo r co ntro l ca bl e and remove
of th e di stribu tion duct so as to gain access to remove heater an d fan co ntrols.
th e two 8 mm nuts holdin g th e air inl et asse mbl y to the 15. Remove four attac hin g sc rews holding centre main air
plen um chamber. di stributi on duct to heater case and remove distribu-
5. Remove th e pl en um chamb er water defl ector and ti on duct.
engin e co mpartm ent seal. 16. Disconnect eva porator drain tube from co nn ec ti on on
6. Remove th e vac uum lead s from th e vac uum tank. und erside of evaporator.
7. Remove th e two bo lts retainin g th e air inl et assembly 17. Remove remaining 1 0 mm nut holding heater housin g
to th e bl ower inl et flange, lift th e air inl et assembly out to das h panel. (Nuts holding evaporator housing to
of th e plenum chamber suffi ciently to di sconn ect hose das h pane l we re removed wh en bl ower assemb ly wa s
from rec irc ul ati on door vac uum actuator and lift air removed; refer item 4).
inlet assembly out of vehicl e 1 8. Lower heater and evaporato r assembly from und er
in strumen t panel , disco nnect vacuu m hoses from ac-
Installation tu ators as soon as they are access ible. Take ca re not
Installation is reverse of removal operati ons takin g care io to damag e demi si ducts.
note the follow ing:
1. Ensure that vac uum hoses are co rrectl y in stall ed and
that recirculati on door mechani sm works co rrectly Installation
before attaching bolts and nuts are in stall ed. Installation is reverse to removal proced ures takin g par-
2. En sure that seals between air inl et and pl enum ticular ca re to note th e foll owin g.
chamber and air in let and bl ower are co rrectly in - 1. Take care not to bend or di stort heater co re and
stalled before tighteni ng attac hin g part s. evaporator tubes when in sta llin g heater and
3. Air inlet cove r shou ld be sealed with non-hardenin g eva porato r assembl y to dash.
sealer to GMH specification HN1 068. Refer Fig.2-5 1. 2. Check with Fig. 2-5 2 for co rrect vac uum hose co n-
necti ons. These hoses should be conn ec ted to th e
actuators before unit is finally install ed.
3. Check heat divert er doo r mec hani sm for full travel and
HEATER AND EVAPORATOR ASSEMBLY free move ment.
4. Chec k with Fi gs. 2-53 and 2-54 for co rrec t wirin g
Removal harn ess co nnecti ons to heater and fan co ntrols.
1. Di sco nnect th e battery negative lead. 5. Use new '0 ' rin g sea ls and lubri cate wi th clean
2. Purge the system . Whi le th e system is discharging, 525 viscos ity refri geran t oil , at th e evaporator pipe
clean the surface dirt from all line co nn ect ions to be co nn ec ti ons.
di sturbed; bl ow away any loose dirt with an ai r hose. 6. Refer to Coo lin g System Sec tion for co rrec t rad iator
3. Wh en the system is co mpl etely disc harged proceed as top up procedure.
foll ows: 7. Evac uate and re charge and performance test system.
1-
u
:::>
0
z
Ul
0
1- I-
w ::>
...J al
I-
::> a:
0 1-
Ul
1-
Ul 0
a: ~ a:
0 w <!
1- 0
u z
\
w
...J <!
lL ~
w
0
a:
'I '
w I •\
I- ' \
<!
s
a:
w
al
~ C/)
<! '!:
I Ill
u c:
0
~ 0.
::J
a: E
0 0
zw 0 (.)
...J 0 c:
a.. z
0
.g
I- 0
~
.5· ~
<! N 'lij
...J
:::> ... ·-
Ill c
u :I ...
a:
~<
0
~
Ill
>
'C
0 Ill
'C
0
a.><
a: w
0
I-
<!
a:
0
a..w
<!al
X::>
WI-
w
>
a:
1\ ~
w
a:
3 a:
:J:::l ~
uz 0...J
<! <!
>I- al
\
0
1\)
I
~
~
<
m
CLIP / B z
::::t
SEAL WITH HN -1068 ALONG

EDGE OF COVER WHERE
s
5
SHOWN THUS :- ~
:I:
SECTION A-A
1-- - -~·- m
(4 PLACES)
~
z
C)
Qo
SECTION B-B ~
:0
(')
0
z
c
-1
0
z
/ z-
C)
REMOVE PROTECTIVE PAPER
FROM FACE OF SEAL AND LAY
SEAL ALONG EDGE OF COVER
AS ~
I
Figure 2-51
Air Inlet Cover Sealing Details
MODE SWITCH
6. DEMIST
\7 HEAT (FLOOR)
D VENTILATE
VACUUM TANK
B BI - LEVEL
**0
COOL OR DRY
VACUUM SOURCE
FROM ENGINE
~ BLACK
I
l
j:
QUICK COOL DOWN
OFF
RECIRC-=-~t~~=-~
ORANGE
BLUE
---------------------------
VACUUM CONECTIONS ON
Qo
~
REAR OF MO D E SELECTOR
LIGHT BROWN
lJ
(")
0
z
c
~
LOWER
0
-zz
MODE DOOR
C)
0
I\)
I
Figure 2-52 ol:lo
Vacuum System Connections 01
0
1\)
I
.c:-.
YELLOW I ; LT. BLUE
ASSE M BLE GREY LEAD TO GREY LEAD
0')
BROWN l I r TAN ON TAPED BACK PART OF MAIN

W IRING HARNESS
<
m
I I I GRE Y /
z
~ [A] :::!
\
- '~ /'h
~- ~]~~~:
~" ~:J ,
-"' -~'..._ ( ~~~-

~-- -
~ ~ ~
,
GENERATOR
MAIN OUTPUT
LEAD
C. -
'- · - - -
~-- ~ / ~
s
0
~/ -- ~~~ ,,
~z
~---- - -------fc-~~~ 0 - -- ~~ ~
MAl~ !ftie'J\_;--
I - "' /'>< /
::I:
~ '~/ / INTERNAL TOOTH m
~-
STR:P T O
"~
'-
"" ~
~
-.. _ / }./;/
//
/
/
LOCKWASHER
ri\1 ~
/h:f~ < ~-~ ~ '~ VI EW~
H ARNESS
z
l ffi] ~ ~/I
~""-RELAY MOUNTING DETAILS,
G)
DRK . GREEN THERM O SW ITCH ). ......_~ J , \\

- \
'-.
( , , ONE RELAY REMOVED
.___ FOR CLARITY
Qo
CONN ECTI ON S '"'- . '\ "-
~
YELLOW .J \
' \ ) JJ
BROWN;;! _), \I /
(")
(\'".,
/l 0
~, / f '-.
/' ::) z
/7
c
y/
;::o... , / - ">:;,
' ~-- ;< >
[J
YELL:~\O
I
~ -~
I I -i
,,
"' 6( / ') 0
-~
-zz
\'
~~'ii\~
{
'
,,. /
I INSERT INTO /
CLOSE CLIP TO 'I G)
CAVITY 12 /
RETAIN HARNESS.
~~
)
~'
Q
Q..
c
~,II ~~- ~r; : \ BLOWER ~1' · LBLACK
/ \
"--~ / "\
25 AMP FUSE DETAILS WIRING -~
/ 'Bl
~
~-P ~\ LEAD
FAN TO WIRING HARNESS

CONNECTION
I '; ;/
'~- ~
\
/ RETAIN VIEW~
~~~~~~~HCLIP~1
~/---"' u . - WIRING MAIN
PLACE
_/ _,;· /.
Figure 2-53
Air Conditioning W iring Harness LS Models
<
m
z
::::t
:)RK. GREEN
YE L LOW _ _l I , s
~~ ~'
~
0
INSERT INTO ___,_, BROWN&. ~z
CAV IT Y 12
:I:
« -r· - =~
>t..-
~-
/ '·
\
II;
-~ .
/11
-....._.,__
~~~ \
(\
~ - ~-~ .-
\-!!-
/_/ ___ I
J_p
I
I(
~LLOW~EAD
m
~
z
~\\\
':j' /
(I ~ C)
I
1) /\ : ~I(~ /St;
--~ ~ -~,~ ~.
ff) ; ' . \\1 I
~.t/c:r 1)~2~/
11 ._/"- ,. _.- _1\ZV QO
~L-- · ·f _../1"~
) ~
Q t...Y-==..~1 - ~Y,C? , ,~ JJ
e__ n
}LACK LEAD
l~ \
- 25 AMP 0
FUSE
z
fOl BLOWER
VIEW~ DETAILS
WIRING c
:::::f
~0 '- \'~'I WIRING HARNE SS 0
\ c. ~J
()Q . )- CLIP-3 PLACES
-zz
C)
0
I\)
I
Figure 2-54 ol:lo
Air Conditioning W iring Harness VS Models ......
EVAPORATOR CORE Installation

Core installation is reverse of the removal procedure taking
Removal ca re to note the following.
1. Remove the evaporator and heater assembly (see 1. Coat all seali ng surfaces n the housing with non-
evaporator and heater removal). hardening sealer to GMH specification HN1 044.
2. Remove the four sc rews holdin g th e evaporator case 2. Ensure that the diverter door hinge bearings are
to th e heater case. correc tl y located in their grooves before assembling
3. Remove th e four sc rews holding the blowe r and the heater core and support assembly into the heater
evapo rator mounting plate, to th e evaporator housing casing.
and gently leve r th e plate away from the housing. 3. When installing heater core and support assembly into
4. Remove the seven sc rews holding the two halves of the case, ensure that the demist door is depressed suf-
evapo rator housing togeth er and carefu lly separate th e ficiently to locate it between the two stops moulded
two halves of the housing. onto the support assembly. (Refer Fig. 2-55) .
5. The evaporator core can now be removed. There is a
fine mesh condensate screen attached to the 'ai r in'
side of the evaporator core. This is held to th e
evaporator core by clips whi ch should be gently re-
moved to avoid damage to th e eva porator co re fin s.
Installation
Evaporator Core instal lation is th e reve rse of th e remova l
proced ure takin g note of th e foll owing po ints.
1. Do not remove caps or plugs from evapo rator co re
tubes until imm ediately before co nn ec ti ons are made
to re frigerant tu bes.
2. When instal ling evapo rator co re into case ensure that
condensate screen is co rrec tl y located and th at seals
between evapo rator core and case are aligned in th e
recesses provided .
3. Ensure that evaporato r case jo ints are coated wi th
non-hardening sealer (HN 1 044) before attac hin g
parts are installed and tigh tened.
Figure 2-55
4. If a new evaporator core is installed add 85 grams of
clean 525 viscosity refrigerant oil. Assembling Heater Core Into Case
EXPANSION TUBE (ORIFICE)

HEATER CORE
Removal
Removal 1. Discharge the refrigerant from the system. (Refer to
1. Remove heater and evaporator assemb ly from vehi c le page 02-31 of this section).
(see sec tion on heater and evaporator assembl y re- 2. Disconnect li qu id line at co upling before thermostatic
moval). switch ca pil lary tu be mounting . (Refer Fig. 2-40) .
2. Remove four sc rews holding heater co re to evaporator 3. Using specia l too l 1 0780 insert tool in pipe to
case and sepa rate th e two casing s. eva porator so that the slots in the tool line up with the
3. Remove the three sc rews attachin g th e inn er support tabs on th e orifi ce tu be. Turn the tool clockwise to lock
frame and heater co re assembly to th e cas in g. On e th e orif ice tube in th e tool sleeve and withdraw the tool
screw is located on th e un dersid e of th e case. Th e to pull ori fi ce tube from the evaporator inlet pipe.
other two are located on th e end panel be hind th e
upper and lower level doo r actuators. Installation
4. Remove the foam seal surroun din g th e heater core Installati on proced ure is as follows:
pipes. 1. Use a new '0 ' ring seal around the orifice tube.
5. With an ass istant holding case firmly, grasp th e heater 2. Wh en instal ling the expansion tube (orifice) inside the
co re pipes and withdraw core and inner support as- evaporator inlet pipe, insert the 'shorter screen end '
sembly from with in case. fi rst and push the expansion tube (orifice) into the pipe
by hand un til it contacts the notched stops in the pipe.
CAUTION: Ca re must be taken to avoid distortion and 3. Evacuate and recharge the system.
damage to hea ter co re and pipes. If difficulty is ex-
perienced wh en attempting to with draw the heater core and
inner support assembly a heat lamp may be placed near
the heater assembly for 5- 10 minutes. Th is will soften the PERFORMANCE TEST
bitumastic sea ler sufficiently to permit removal of the
heater co re and support assembly. PROCEDURE
6. Remove th e sc rews holding th e heater core to the Under normal circumstances, it will not be necessary to
sup port frame and remove the heater core. performance test an air conditioning system , however, the
test can be used to confirm a reported ma lfunc tion or in- through radia tor grille and condense r, and the tem-
efficiency in the system and should always be used to perature of the air, en tering the cowl
determine if the system is performing satisfactori ly fol - 9. A thermometer placed in front of the vehi cle grill e and
lowing any component rep lacement which invo lves dis- another in one of the centre air condi ti onin g outl ets.
charging the refrigerant.
The following fixed conditions must be adhe red to in order
to make it possible to compare the perfo rmance of the PERFORMANCE DATA
system being tested wi th the appropriate performance The Pe rformance Data Table defines normal operation of
data. th e system under dry and humid cond ition s. Local weather
1. The car inside or in the shade. repo rts will give a guide to the humidity level.
2. Engine hood and front doors open and engine exhaust NOTE : Before removing the gauges, as a safety
suitably ventilated. measure ,crack open both manifold hand valves to balance
3. Gauge set installed as shown in Fig . 2-56 th e hig h and low side pressures. Close the valves and
4. Vehicle in neutral with engine running at 2000 rpm . disconnect both hoses at high and low pressure fitting s on
(Park for automatic transmission eq uipped vehicles). compresso r and acc umulator.
5. Mode control lever set for maximum coo ling and hig h NOTE : Hi gher tempe rat ures and pressures will occur at
blower speed selected. hi gher ambi ent tem peratures. In areas of very high humidity
it is poss ibl e to have thermometer and gauge read ings
6. Temperature control lever set at COLD posit ion, air
approac h but not reac h th e fig ures listed in th e perform -
co nditi on ing outlets open.
ance data tabl e and still have a satisfactory operating unit.
7. System settled out, i.e., run for app roximately However, it is important to remember that low pressure has
5 minutes under th e above conditions. a di rect re lationship to outlet air temperature. If pressure
8. Place a high volume industrial type fan in front of the is too low, ice wil l gradua lly fo rm on the evaporator fin s,
radiator grille blowing into the condenser to ensu re restricting ai rfl ow in to the passenger area and resu lt in
minimum difference in temperature of air passing insufficient or no cooling.
AIR CONDITIONING DA T A TA BLE
AMBIENT AIR - D EGREES C AVERAG E A CCUMU LATOR

AV E RAGE COMPR ESSOR HEAD CENTRE OUTL ET AIR
.\UXILIARY FAN AIR BLAST AIR QUA LIT Y V A LVE PR ESS kPa
PRESSURE - k Pa TE MPERATURE DEGREES C
AH EAD OF CO N DE NSER A T SEA LE V EL
DRY 965 - 1035 205 - 2 10 4 .5 - 6

20
HU M ID 1070 - 1140 205 - 2 10 6 - 8
DRY 1070 - 1175 205-210 6- 8

25
HUMID 12 10 - 1280 205 - 210 8 - 10
DRY 1245 - 1350 205 - 210 8 - 10

30
HUMID 1385 - 1490 205 - 2 10 10 - 12
DRY 1455 - 1595 205-210 10 - 12

35
HUMID 1630 - 1770 205-210 12 - 14
DRY 1735 - 1875 205 - 225 12 - 14.5

40
HUMID 1910 - 2120 215 - 235 14.5 - 16.5
DRY 2050 - 2190 205 - 240 14.5-17

45
HUMID 2260 - 2505 235 - 255 17 - 19
0
1\)
I
CJ1
SUCTION HOSE DISCHARGE HOSE 0
<
m
z
COMPRESSOR :::::!
(TOP VIEW)
....--
E
5
ADAPTOR HIGH PRESSURE ~
GAUGE CONNECTION
LOW PRESURE :J:
GAUGE CONNECTION m
VALVE
LOW PRESSURE
GAUGE MAN IF OLD & GAUGE SET
~
z
C)
Qo
)>
GAUGE LINES :0
()
ACCUMULATOR
0
z
VACUUM CONTROLL VALVE
c
CYLINDER
-4
FILL VALVE 0
z
z
____.;-;-B LEED VALVE C)
REFRIGERANT
CYLINDER
VACUUM PUMP
CHARGING CYLINDER
Figure 2-56
Connections For Performance Test
REFRIGERANT CIRCUIT TROUBLE DIAGNOSIS GUIDE
INSUFFICIENT COOLING QUICK-CHECK ACCUMULATOR ASSEMBLY

PROCEDURE The accumulator assembly for th e CCOT system wi ll have
The foll owing CCOT 'Hand - Feel' procedure can be used to a se rvice replacement whi ch includ es two '0 ' ring s (for th e
quickly determine whether or not th e system has th e proper in let and ou tl et connections). Th e des iccant wi th in the can
cha rge of refrigerant (providing ambient temperature is is NOT serviced separately - it is part of th e sea led ac -
above 21 deg . C. This check can be made in a matter of cumul ator assembly .
minutes, simplifying system diagnosis by pinpointing the The accumulator assembly should ONLY be replaced
prob lem to the amount of charge in th e system or by when :
elimina ting this possibility from the over-all checkout.
1. A physical perforation to th e acc umulator is found ,
1. Eng in e must be warm (choke open and off fast idle resu ltin g in a leak.
speed cam) . 2. The expansion tube (o rifi ce) sc reen is plugged .
2. Hood and body doors open .
3. The com pressor inlet sc reen is plugged .
3. Se lector lever set at NORM . 4. An evapora tor fail s because of inside-out (internal )
4. Temperature leve r at COLD . co rros ion.
5. Blower on HI. DO NOT replace th e accumulator assemb ly wh en:
6. Normal engine idle. 1. Merely a den t is fo un d in th e outer shell of th e ac-
7. ' Hand -Feel' temperature of eva porat or inlet pipe nea r cumul ator.
th ermostati c switch capi ll ary tu be con necti on AND 2. A vehicle is involved in a collision and no physical
accumulator can surface with com presso r engaged . perfo ration to th e acc umul ator is found . An open re-
(a) BOTH SA ME TE MPERATURE AND SO ME DE - frigerant line should be capped or have a plasti c bag
GREE COO LER THAN AMBIENT - Proper co n- tightl y taped around it.
diti on: check for oth er probl ems.
(b) INLET PIPE COO LER th an accumu lator surfa ce - CONDENSER
low refrigerant charge . A co nd ense r may be defective in two ways; it may leak, or
Add slight amoun ts (.12 I) of refrigerant UNTIL it may be res tri cted. A co nd enser restriction will res ult in
BOTH feel th e same temperature. Allow excess ive co mpressor d isc harge pressu re. If a partial re -
stab ilizati on tim e between add iti ons. stri cti on is present, sometim es ice or frost will form im -
Then add .4 2 I additional refrigerant. mediately after the restriction as th e refrigerant expand s
(c) INLET PIPE HAS FROST ACCUMULATION - ac- after passin g through th e restriction . If ai r flow through the
cumulator surface warmer; proceed as in Step b condenser or radiator is blocked , high discharge pressures
above . will result. During normal condenser ope rati on , the ou tl et
pipe wi ll be sli ghtly coole r than th e inlet pipe .
THERMOSTATIC SWITCH DIAGNOSIS
EVAPORATOR
1. In stall Ga uge Set and set up th e vehicle as desc rib ed
un der 'Pe rforman ce Co nd iti ons' in previous 'System When th e evaporator is defecti ve, th e troubl e wi ll sho w up
Diagnos is' Procedure. as an inadequate supply of cool air. A partiall y plu gged
co re due to dirt, a cra cked case, or a lea kin g sea l wi ll
2. Set th e control at NORM mode, Lo bl ower. The th er-
gene rally be th e cau se.
mostati c switch shoul d cyc le th e com pressor off in
5 min utes or less . If th e compressor operates con-
REFRIGERANT LINE RESTRICTIONS
tinuously and th e accumulator frosts, thi s is an ab-
normal cond iti on and will lead to eva porat or freeze- up . Rest ri cti ons in the refrigerant lines will be indicated as
The problem is ei th er loose clamps around th e foll ows:
capil lary tube to th e evapo rator in let pipe or a de- 1. Suction Line- A restricted sucti on lin e will cau se low
fective switch. suction pressure at the co mpresso r, low di sc harg e
If the compressor does not ope rate, thermostatic pressu re and little or no coo ling .
swi tch is defective (provided that it has been estab - 2. Discharge Line- A restri cti on in the discharge line
li shed th at battery vo ltage is avai lable at one swi tch generally will cause the pressure relief valve to open.
terminal with Air Condi ti oning 'on ' and battery voltage 3. Liquid Li ne- A liquid line restriction will be evidenced
is not available at compressor cl utch) . Thi s, of co urse , by low discharge and su ction press ure, and insuffi cien t
results in no cooling . Replace the swi tch . cooling , ice or frost will sometim es form on the liqui d
The th ermostati c swi tch is pre-set and canno t be line in the area of the restriction .
adj usted .
Preliminary checks C.C .O.T . AIR COND IT IO Nir'II G DIA GNOSIS 0
1. Blower operation. N
I
INSUFFICIENT COOLING
2. Damaged or missing c.n
evaporator drain hose. N
3. Air duct connections.
4. Functional test of
system
•
Check for compressor
clutch operation. <
m
5. Proper sealing of
NGAGED OR CYCLING OF ALL TIME
z
evaporator or
t :::!
s
mod u le case.
6. Heater Door Feel liquid line ahead of Check compres!or feed with test
functioning. expansion tube (orifice) light or place jumper wire from
the compressor to positive(-)
5
r-- I t NO T ENGAG ED
- · terminal If battery.
ENGAGED
~z
:I:
COLD WA R M
I ~ m
l ! Apply external ground
to compressor. I f clu t ch
Check for blown main fuse
~
Restriction in high side Feel evaporator inlet pipe near is still not engaged remove ~ z
of system. Visually look thermos t atic swi t ch compressor for clutch overhaul. Check for open circuit G")
for frost spot to locate tube connection and accumulator at the following
restriction. Repai r can surfa ce. I QO
evacuate & recharge. I ------.
A LL SW ITCH ES THERMOSTATIC )>
CHE CK O K SW ITCH
JJ
~ (')
l
I NLE T PI PE & ACC U MU L A T OR SU RF ACE
SAM E TE MPERA T URE OR
INLET PIPE CO LDER
T HAN ACCUMU L A T OR SUR F ACE
Check for broken wire
or loose con nec ti on in
comp ressor cir cu it
~
Replace switch
* 0
z
c
3
ACCUMU L ATOR SU R FACE CO L D ER TH AN INL ET
! Repa i r or replace
0
~
I nstall thermometer in A/C Outlet and carry out perfor-
L eak check system & repair leak. If no
leak is found . Check expansion tube
(orifice) for plugged filter. Evacuate &
r-- - z
z
recharge. R echeck inlet pipe and accumu- B E LOW 150 KPa ABOVE 150 K Pa G")
mance check
lator surface temperatures.
~
Lost charge
t
Jump press, switch
leak test and
!
STILL COLD AND SAME T EMP (COLD)
repair. Evacuate
and recharge
l
Compressor runs
WARM AS ABOVE OR ACCUMU L ATOR
COLDER THAN I NLE T l
Replace Switch
Replace expansion
l
System
Evacuate & recharge
tube (orifice) and Normal

evacuate and
recharge
(CONTINUED ON NEXT CHART)
Figure 2-57
CCOT Air Conditioning Diagnosis
COrH I NUED
l ~
OUTLET TEMPERATURE OK OR OUTLET TEMPERATURE
TOO COLD AS PER CHART HIGH AS PER CHART
~
Change blower speed
t
Check accumulator pressure
r-
~
to low and observe
accumulator and evaporator
pipes for frost
1 LOW
(as per chart)
HIGH TO NORMAL
NO FROST FROST
!
Plugged expansion tube (orifice) repair l
or replace. Replace accumulator Check compressor cycling
+ ~ assembly and evacuate & recharge system
System
Normal
Replace thermostatic
switch t u-- n -
I•
ON CONTINUOUS L Y CYCLES ON AND OFF MORE

THAN 4 TIMES PER M I NUTE
! l <
m
Check for missing Replace thermostatic z
expansion tube (orifice) switch
::t
f
M ISSI NG IN PLACE ~
0
l
'
In stall ex pans ion tube (orifi ce)
evacua te & recharge
Check compressor
inlet screen
~z
J:
r -- m
PLUGGED C LE AN ~
zG')
!
R epair or replace screen
l
System over charged Qo
replace accumulator assembly evacuate & recharge
evac uate & recharge )>
:tl
(OUTLET T EMPERATURES SHOULD BE TAKEN JUST BEFOR E COMPRESSOR CLU T CH RELEASES) (')
0
z
c
~
0
-zz
G')
0
1\)
I
Figure 2-58 CJ1
CCOT Air Conditioning Diagnosis (Cont 'd) w
NOTES
FRONT SUSPENSION 03-01
SECTION 03
FRONT SUSPENSION
Subject Page Subj ect Page
GENERAL DESCRIPTION ............................................... 03-01 WET STRUT SERVICE KIT REPLACEMENT ...... 03-10
MINOR SERVICE OPERATIONS ................................... 03-03 Armstrong York Wet Strut .............................. 03-10
JACKING PRECAUTIONS .............................................. 03-03 Rem oval .............................................................. 03-10
WHEEL ALIGNMENT ....................................................... 03-03 Installation .......................................................... 03-10
PRELIMINARY INSPECTION .................................. 03-03 Wylie Wet Strut ................................................. 03-10
CASTER AND CAMBER ADJUSTMENT .............. 03-03 Removal .............................................................. 03-10
To Adjust ............................................................ 03-03 Installation .......................................................... 03-10
TOE-IN ADJUSTMENT ............................................. 03-03 FRONT STRUT ASSE MB LY ............................ ........ 03-11
SUSPENSION HEIGHT CHECK ..................................... 03-05 Installation .......................................................... 03-11
FRONT WHEEL BEARINGS ........................................... 03-05 CONTROL ARM ................................................................ 03-11
REMOVAL HUB ASSEMBLY .................................. 03-05 REMOVAL .................................................................. 03-11
Inspection ........................................................... 03-05 INSTALLING CONTROL ARM ................................ 03-11
To Replace Bearing Outer Cups ................... 03-05 TO REPLACE TENSION ROD BUSHING IN
Installation of Bearings and Seal .................. 03-05 CONTROL ARM ........................................................ 03-12
Wheel Bearing Adjustment ............................. 03-06 TO REPLACE TENSION ROD BUSHING IN
STABILIZER BAR ............................................................. 03-06 CROSSMEMBER ASSEMBLY ................................. 03-12
REMOVAL .................................................................. 03-06 TO REPLACE CONTROL ARM INNER
INSTALLATION .......................................................... 03-07 PIVOT BUSHING ....................................................... 03-13
MAJOR SERVICE OPERATIONS ............ ...................... 03-07 LOWER CONTROL ARM BALL JOINT ....................... 03-13
FRONT SPRING ................................................................ 03-07 INSPECTION .............................................................. 03-13
REMOVAL .................................................................. 03-07 TO REPLACE ............................................................. 03-13
INSTALLATION ..................... ..................................... 03-08 FRONT CROSSMEMBER ................................................ 03-14
SUPPORT BEARING REPLACEMENT ......................... 03-09 REMOVAL .................................................................. 03-14
INSTALLATION .......................................................... 03-09 SPECIAL TOOLS .............................................................. 03-15
FRONT STRUT ASSEMBLY ........................................... 03-09 SPECIFICATIONS ............................................................. 03-16
REMOVAL .................................................................. 03-09 TORQUE WRENCH SPECIFICATIONS ........................ 03-16
GENERAL DESCRIPTION
The front suspension (Fig. 3- 1) utiliz e th e Mac Ph erso n arms to th e c rossmember, the ten sion rods are mounted on
strut principle. Th e assembly co nsists of the front cross - flexibl e rubber bushes at each end .
member, lower co ntrol arm s, ten sion rods, stabi li ze r bar A stabi lizer bar is mounted to th e lateral frame side
and strut assemblies . members by two brackets and in sulating rubb ers, and
attached to each lower control arm by a stud , in sulating
Th e c ross member is bolted to both lateral fram e sid e rubbers , washers, spacer and attaching nut.
members, th e inner pivots of th e lower con trol arms are For production and se rvice , st rut assemblies are obtain ed
rubber bushed and and attached to th e c rossmember by from two different so urces . The assemblies fitted to
bol ts. Th e outer end is co nnected to th e knuc kle on th e strut vehicles with six cylinder engines are manufactured by
assemb ly th ro ugh a ball joint. Armstrong York and vehicles with eight cylinder engines
The strut assemb ly in co rp orates a hydrauli c wet sleeve are fitted with strut assemblies manufactured by Monroe
type damper inside the outer tube, and a coi l type sus- Wylie.
pen sion sprin g mounted between th e strut housin g and The struts are readily identified by the colour of th e outer
upper support bearing assemb ly. tube assembly , Armstrong Yo rk are painted black and
The damper shaft is moun ted at th e upper end to th e body Monroe Wylie are painted dark blue.
structure th ro ugh a ball bearing thru st ra ce pressed into th e Strut assemb li es fitted to six and eight cylind er vehi cles are
upper bearing supp ort plate ; the outer race support is physica lly interchangeable, however, as th e shoc k ab-
bond ed to th e plat e by a rubber insulator; th e lower end of so rb er calibrati ons are different two se rvi ce repl acement
the strut tube is pressed into the stee rin g knuckle. kits are released , one for Armstrong struts and one for Wyli e
Fore and aft location of th e lower co ntrol arm assemb li es struts. It is important to ensure that the co rrect repl acement
is co ntroll ed by tension rods co nn ectin g th e lower co ntrol kit is used during st rut overhaul.
0
(1.)
I
0
~
1\,)
& BOLT
ffi NUT ---- ~ "T1
::0
\
-1r / /
/
ill NUT~
SHIM~
-_;, •.J ._
0
z
-4
® ..;;;,~ - .lcnc ~~
\\ ~ s "~ CJ)
..
<.,>.
/~· I
BUSH r-;,.
(6 PLACES) "-...._ ~
cCJ)
0---
~-·""'"' ~ "tJ
,.
' ~- m
_:.~~ z
';_, - .....,--
I
FRONT SUSPENSION
CROSS MEMBER ~~ CJ)
0
I
I
®~sTAB BAR z
I
(c'~
@
PL ATE
t~STUD 1
INSULATOR --- ~ .: -. __ eI /,,_*'I I'~
r::
~ ~
~A
'i:idf jJ_. I
SU PPORT -
~~
'~~~ ~~'\_ \~,~
'@foL.
- -·
~ -------=:5l3
- ~~ \ NUT
1.\
E:,
~ BOLT -
------- 10J .... I
~~~ f p
. . \_ WASHER
STABILIZER BAR/ TENSION ROD PLATE j

LOWER CONTROL ARM
/®._______R ETAINER
WAS HER -'
~
ffi 95-110Nm.
BUSH -ASS EMBLE WITH SPIGOT IN HOLE
g 40- 55 N m. (2 PLA CES)
£ 20- 25 Nm.
L~ 12-16N m.
Figure 3-1
Front Suspension Assembly
MINOR SERVICE OPERATIONS

JACKING PRECAUTIONS
When raising the front of th e vehicle with a garage ja c k, th e
jack should be placed under the front c rossmember. The
weight of the vehicle must not be lifted under the lower
control arms.
Wh en the ve hi cle is rai sed on the jack it must be firmly
supported on safety stands located und er the frame side
members befo re any wo rk is attempted. Serious injury can
occ ur owing to a vehicle not being supported by safety
stand s, slipping off the jack.
WHEEL ALIGNMENT
PRELIMINARY INSPECTION
Before any attempt is made to check camber, caster or
toe-in th e foll owing preliminary checks should be ca rried
out.
1. Check lyre and tyre mountings. Always check
camber and toe-in at th e mean run-ou t posi tion on th e Figure 3-2
lyre or rim . Support Bearing Mounting
2. Check and adjust ty re press ures to recommended
values .
3. Front wheel bearings should be co rrectly adju sted.
4. Lower co ntrol arm ball joints and inner bushes shou ld Raise the strut and install th e mounting nuts and washers .
be chec ked for wear. Torque nuts to 20-25 Nm .
5. Check steering gear mounting bolts for tightn ess and TOE-IN ADJ USTMENT
the ti e rod ball joints for wea r.
Toe-in, the inward pointing of both front wheel s, is checked
6. Th e vehicle shou ld be at kerb load , fuel tank full,
wi th the wheel s in the st raight ahead position and the
withou t drive r, passengers or luggage etc.
steering wheel set in th e co rrect straigh t ahead driving
positi on.
CASTER AND CAMBER ADJUSTMENT
1. Set the steering gear rack in the mid (straight ahead)
Only a nominal change in the caster and camber ang les is position by turning the stee rin g wheel from one stop
possib le. This is achieved by rotating the support bearing posi tion to the other and counting the total number of
1 20 degrees to the front (C) or 1 20 degrees to the rea r (0) turns, then turn the wh ee l back exactl y half way to th e
of th e vehicle as shown in Fig . 3-2. In either direction a ce ntre position .
pos itive ca mbe r co rrection is made, with a small c hange
to the pos itive or negati ve caster angle as shown in the 2. Before adjusting the tie rods , slid e the outer clips off
following chart: the boots.
3. Loosen the lock nut at the end of each ti e rod.
4. Turn each tie rod as required, until correct toe- in is
CAMBER CASTER obtained , refer Fig . 3-3.
CORRECTION CHANGE
5. Tighten lock nuts, ensuring that the tie rod ends are in
Rotation in Direction "C" +10 - 0°30 I alignment with th eir ball studs, then reinstall the boot
retainer c lips after making sure that th e convolutions
Rotation in Direction "D" +10 + 0°30 1
of the boot are not distorted.
To Adjust
Rai se the fron t of the vehicle using a lifting jack und er th e
fron t crossmember and support on sa fety stand s under the
fron t sid e member. Refer jacking precautions at th e front
of thi s sec ti on.
Li ghtly take the load of th e strut assembly with a jack
placed und er the lower con trol arm and remove the three
nuts and wa shers sec uring the support bearing to th e
spring strut towe r shown in Fig . 3-2.
Lower th e jack far eno ugh to c lea r th e studs on th e support
bearing plate from th e sp ring strut towe r.
Rotate th e support bearing 12 0 degrees to th e front or rea r
as req ui red to make th e co rrec tion , refer to Alignment Chart
Fig . 3-3.
0
wI
0
~
"'T1
JJ
X 0
z
' CAMBER + 1a,

-i
CJ)
cCJ)
'"0
m
z
CJ)
\ CASTER - Oa30'
FRONT 0
! z
___ j \
) - CAMBER • 1°
CASTER + oa30
~ INSTALLATION
OU TB OAR D
V IE W X MARK ON
R El N FORCEM ENT -W HEE LHOUSE
CAM B ER & CAS TE R
ADJ UST M ENT .
. -_L
~---.,-___/ G RO U N D
FRONT WH EEL ALIGNMENT AT KERB WEIGHT*
CAS T ER 1a·30' ± 1a
CAMBER _,a ± Oa30 '
THE A DJ UST I NG VALUES FOR CAMB ER TOE-N (DEGRESS) TOTAL oa 20' ± Oa20'
& CA STE R MUST REMAIN W ITHI N T H E
T O L ER ANCE SPECI FI ED & T H E DI FF ER EN C E TOE- I N (mm) TOTAL 2,0 ± 2,0
BETW E EN L EFT & RIGH T MUS T NOT EXC EE D 1a01
-
*W IT H FU LL FUE L TANK (46 kg)
Figure 3-3
Front Wheel Alignment Chart
SUSPENSION HEIGHT CHECK Inspection

Th e front and rear height chec kin g dim ensions li sted in th e Check bearings for cracked bea rin g cages , worn or pitted
foll owin g chart, are a nominal dim ensi on measured from rolle rs and bearing cones and cups for cracks and evi-
th e und ersid e of th e fend er opening to the lower edge of dence of scoring.
th e wh eel rim , as shown in the Suspension Height Chec k Chec k th e bea ring outer races for looseness in th e hub.
Di ag ram below. Th e dim ensions are for a new car and only Chec k to ensure th at the inner cones of th e bea rings are
intend ed as a guid e wh en chec king vehi c le heights at free to revo lve on the stee ring knuckle.
normal kerb load . Normal kerb load is defin ed as a car with
Check hub bol ts to ensu re threads are not damaged , and
a full tank of petrol, water, oil , spare tyre,spec ifi ed lyre
that bolts are pressed firm ly in to the hubs.
press ure and no passeng ers.
Acc umul ated dirt, mil eage, etc., must be taken into con-
side rati on wh en chec kin g ve hi c le heights.
CAUTION: Good j udgement must be exercised before To Replace Bearing Outer Cups
replacing a spring or springs from a car wh ose kerb height Drive out th e cup usin g a suitabl e brass dri ft , tapping ligh tly
is only slightly out of limits, a vehicle ca n be low but around the circ umference of the c up.
measure about th e same at loca tions and still be ser- Press a new cup into th e hub makin g sure that the cup IS
vicea ble. Spring replacement under co nditions of ex- not cocked and that it full y seats ag ainst th e shoulder in th e
cessive weight due to non stan dard fittings, undercoating, hub.
road dirt, etc., will assist very little in restoring th e vehicle
to its specified height.
Installation of Bearings and Seal

Th e bearings should be pac ked wi th wheel bearing grease
conformin g to GMH speci fica ti on HN 1 227 . Apply 5 grams
FRONT WHEEL BEARINGS to th e inn er bea rin g and 3 grams to th e outer bea ri ng .
NOTE: Do not pack th e hub bea rin g cove rs or the hub
REMOVAL - HUB ASSEMBLY Fig. 3-4 betwee n the inner and outer bea rin g assembli es, as ex-
cess ive lub ricati on results in the lubri cant workin g out on
Loose n front wh ee l retainin g nuts, rai se ve hi c le and pl ace
th e brake pad s. Heavy fi brous type bea ri ng lubrican t
on sa fety stands and remove th e road wh ee l. Refer jac kin g
should not be used with roll er bea rin gs.
preca uti ons at th e front of this sec ti on .
Ins tall a new wheel hub bearing sea l, th e lips of the seal
Remove th e brake caliper and suspend on wi re or hoo k to shoul d be lubricated with grease to GMH speci ficati on
avo id strai n on th e hose . HN 1 22 8 before insta llati on. Th e oil seal locates firmly on
Remove th e inn er and outer bea ring from th e hub and wash th e ax le spindl e and th e hub rotates aroun d the three
all parts th oroughly in clea nin g solvent. stati onary sealin g lips of th e sea l.
SUSPENS ION HEIGHT (N OMINAL)

MODEL R IM SIZE
FRONT REAR
D IME NSION "A " D IMENSION "B"
8VK69
Co mmo d ore Sedan 14 X 600 JJ 587 mm 555 mm
8V L69
Co m mod ore 'S L ' Sedan 14 X 600 JJ 58 7 mm 553 mm
8VX 6 9
Co mmo dore 'S L E' Sedan 15 X 6 00 JJ 593 mm 555 mm
A B
Suspension Height Check Diagram
03-06 FRONT SUSPENSION
Wheel Bearing Adjustment STABILIZER BAR

1. Hand spin disc and sn ug up sp indl e nut to fully seat
A front stabilizer bar is fitted to all Model s, refer Fig . 3- 1.
bearings.
The bar is attached to the frame side members by rubber
2. Back of nut until just loose (1 / 4-1 /2 turn). insulators and brackets. The outer ends are attached to th e
3. Hand snug up the nut. lower control arms by connecting studs, in sulator plates
4. Loosen nut until either hole in spindle lines up with slot and rubber insulators.
in nut.
5. Install cotter pin and lock securely. REMOVAL
To remove the stabilizer, raise front of vehicle and support
CAUTION: Under no circumstances is the nut to be even on safety stands. Refer to jacking precautions at the front
finger tight. of this section.
Remove the nut securing the stabilizer bar stud on each
Reinstall the brake caliper and road wheel. Tighten the control arm
caliper attaching bolts to specification (refer Brake Sec-
Remove the bolts securing the suppo rt bracket to each side
tion) and the road wheel attaching nuts to specification,
member and remove the stabilizer bar.
refer Wheel and Tyre section in this Manual.
i--- _,~
~.'
~----t--- - ~
I ::::.--.....__~
KNUCKLE & STRUT ASM -STEERING
I
!.: =-
INNER BEARING
OUTER BEARING
WASHER
NUT
COTTER PIN
COVER
SEAL -
HUB AND DISC ASM
Figure 3-4
Front Hub Assembly
INSTALLATION
Assemble the two insulators and support brackets to th e
stabili ze r bar and bolt th e brackets to th e si de members.
The slot in eac h insulator should be in a forward direction
as shown in Fig. 3-5.
Install the stabilizer studs to the lower control arms with th e
plates and insulators in stalled in the order shown in
Fig . 3- 1. Tighten attaching nuts on stabilizer studs to 12 -
16 Nm .
Figure 3-5
Correct Location of Stabilizer Bar Insulator
MAJOR SERVICE OPERATIONS
FRONT SPRING
REMOVAL
1. Loosen front road wheel attach in g nuts. Raise front of
vehi cle und er th e c ross member and place safety
stand s under th e side members. Refer to jac kin g
preca uti ons at th e front of thi s secti on.
2. Remove front road wh ee l, and remove the brake hose
from th e bracket on th e strut by turning the plastic
sleeve on the hose until the flats on th e sleeve line up
with the opening in the bracket.
3. Insert the th readed end of the three hooks through the
holes in the half plates of sprin g co mpresso r Tool
No. AU148 and c lamp the two half plates to the strut
tube. Attach the upper ends of the hoo ks to th e sp ring
coi ls as shown in Fig . 3-6 and instal l the three nuts to
the threaded end s of the hooks.
4. Pl ace a lifting jack under the outer end of the lower
control arm and raise far enough to co mpress the
spring.
5. Tighten the three nuts on the spri ng comp resso r to
hold th e spring in the compressed position .
6. Raise th e engine hood and prise the dust cap from the
upper bearing support. Figure 3-6
7. Hold th e strut rod shaft using a suitable spanner across
Spring Compressor In Position
th e flats or sc rewdriver in the slot and remove the se lf
loc king nut and shim using strut rod nut wrench tool
No . AU1 57.
NOTE : If th e strut rod nut is excessive ly tight, holding bar on th e bearing support plate and sp ring strut towe r so
too l No. AU177 is available for holdin g th e shaft. Under no that they can be reassembled in the same position,
ci rcum stan ces is th e shaft to be gripp ed directly on the seal refer Fig. 3-12.
area of the shaft. 9. Lower the lifting jack supporting the lower control arm,
and remove the upper bearing support, spring seat,
CAUTION: Do not attempt to remove th e self locking nut and insulator from the top of the spring.
from th e strut rod shaft before compressing the spring. 1 0. Pivot the strut assembly on the lower ball joint far
8. Remove the three nuts and washers attaching the enough to allow removal of th e spring from the side of
upper bearing support plate to th e spring strut tower, the vehicle. (Fig. 3-7)
obse rvin g th e position of the wheel alignment marks 11 . Release the spring compressor and remove the sp ring .
d)
PACK BEAR I NG WITH
APPROX 5m l OF
t= ----
- - CAP
__ NUT
'f .
WH EEL BEAR I NG GREASE SHIM
~~ ~~2~.SPECIFICATION ~ UPPER BEARING

. SUPPORT ASSEMBLY
SEA LIN G PLATE
PART T O BE A SSEMBLED ~L_ ___ SEAT FRONT

WITH NO T CH IN UPPER ~ ~- SPRING UP PER
FLANGE O UTBOARD I .E. a:=il' ~
·· ""
IN LI N E WITH WHEEL ~- I NSU LAT OR
SPINDLE. I
~:~::ER
Figure 3-7
~ FRON T SPRIN G
Strut Assembly Positioned for Spring Removal
D ISC AND KNUCKLE

ASSEMBLY
INSTALLATION
1. Positi on th e repl ac em ent sprin g on th e strut with the
straig ht projectin g end of th e spring co rrectl y located
in th e lower sprin g seat.
2. In stall th e insulator and upper spring seat so that th e
notch in th e upper flange on the spring seat is as-
sembl ed outboard . i.e. in line with th e wheel spindle
Fig. 3-8.
Figure 3-8
3. Repos iti on th e strut assembly under the guard, th en Front Spring Installation Lay-Out
instal l th e bearin g sealing plate with the edge pointing
upward as shown at 'A' in Fig . 3- 9.
4. Lubri cate th e upper support bearing wi th 5 ml of wheel
bearing grease to GMH Spec ifi cation HN 1227 and
install the assembly on the strut rod shaft. Loose ly
install the shim and self loc kin g nut to the shaft.
5. Ra ise the jack under th e lower control arm , at the same
tim e gui de the three stu ds on th e upper bearing
support pl ate through th e mountin g holes in the sprin g
strut tower.
IMPORTANT: Make sure that the wheel alignment marks on

the upper bearing support plate and spring strut tower are
reassembled in th e same position as noted in step 8 during
disassembly.
6. In stall th e wash ers and self locking nuts to th e stud s
on th e support plate and torqu e to 20 - 25 Nm .
7. Torqu e th e nut on th e strut ro d to 60-85 Nm using strut
rod nut wren c h too l No. AU1 57 togeth er wit h a 'Un i-
ve rsa l' Torqu e Wrenc h.
8. Remove th e sprin g compresso r. Rein stal l th e brake
hose in th e brac ket.
9. In stall th e road wh ee l and tighten attac hin g nuts to
spec ifi cati on, refer Wh ee l and Tyre secti on in thi s Figure 3-9
Manu al. Upper Support Bearing Installation
SUPPORT BEARING REPLACEMENT 7. From inside the engine compartm en t remove the three
nuts and washers attaching the upper bearing suppo rt
NOTE: The support plate and bearing are serviced as an plate to the spring strut tower.
assembly and must not be disassembled. 8. Remove the strut assembly from th e vehicle observing
the location of the installation mark 'A' in relation to
REMOVAL mark 'B' (Fig. 3-12) on the spring support bearing and
Follow steps 1 to 9 as described for Front Spring Removal. spring strut tower to ensure that they are installed in
the same position on reassembly.
INSTALLATION NOTE: The marks 'A' and 'B' aligned as shown in Fig. 3- 12
Follow steps 4 to 9 as described for front spring installation . are the factory setting marks for camber and caster.
FRONT STRUT ASSEMBLY
REMOVAL
1. Loosen the front road wheel attaching nuts. Raise the
front of the vehicle under th e crossmember and place
safety stands un der the side member. Refer to jacking
precautions at the front of this section.
2. Remove the road wheel , remove the brake hose from
the bracket on the strut by turning the plastic sleeve
on the hose until the flats on the sleeve line up with the
opening in the bracket. Remove th e brakes caliper and
support on a piece of wire, so that the weight of the
caliper is not taken by the hose.
NOTE: To remove the st rut assembly from the vehicle it is
not necessary to compress the front sp ring .
3. Remove the split pin and nut from the steering tie rod
ball joint stud and press the stud out of the steering
arm using Tool No. 9A 1 0.
NOTE: It will be necessary to rework Tool No. 9A 1 0 by
grinding a small radius on the outside of one leg to clear
the tie rod extension on the ball joint.
4. Remove the stabilizer link bolt from th e control arm.
5. Remove the split pin and nut from the ball joint stud
and press the stud out of the steering knuckle using
Tool No . AU152 Fig . 3-10.
6. Using a suitab le bar, prise the ball joint stud out of the Figure 3-11
steering knuckle (Fig. 3-11 ). Prising Ball Joint Stud From Steering Knuckle

Removing Ball Joint Stud From Steering Knuckle Factory Setting Marks for Camber and Caster
WET STRUT SERVICE KIT REPLACEMENT

1. With th e strut assembl y removed from th e vehicle,
mount th e assem bl y in an upri ght positi on in a vice, to
avoid spilling the fluid when th e strut rod and sleeve
are removed .
CAUTION: The assembly must be held by the knuckle. Do

not grip th e tube in a vice as damage could res ult.
2. In stall th e spring co mpresso r Too l No. AU 148 as
previous ly described for sp ring remova l, and compress
th e sp ring .
3. Remove th e se lf lock in g nut from th e strut rod shaft.
Using strut rod nut wrench too l No. :'l.lJ 157.To prevent
the shaft turning, use a spanne r across the flats or a
suitable screwdrive r in th e slot on the end of th e shaft.
NOTE: If the strut rod nut is excessive ly tight a holding bar
too l No. AU177 is availab le for holding th e shaft. Under no
c ircum stan ces is the shaft to be gripp ed directly on th e sea l
area of th e shaft.
CAUTION: Do not attempt to remove th e self locking nut

from th e strut rod shaft before first compressing th e spring.
4. Remove th e upper bearing support , bearing sealing
plate, sprin g seat and insulator from th e top of th e
spring , toge th er with bumper stop and pl asti c boot.
STRUT ROD GUIDE
5. Replace th e wet strut with a se rvi ce kit as foll ows: AND SEAL
Armstrong York Wet Strut (Fig. 3-13)
Removal
A. Usi ng Too l No . AU156 rem ove th e gland nut from
th e strut.
Figure 3-13
B. Withdraw the strut rod sufficien tl y to remove th e
Armstrong Wet Strut
'0 ' rin g, strut rod guid e, and sea l assemb ly.
C. Remove the strut rod assemb ly and cy lind er from
the strut.
NOTE: When withdrawing th e strut rod and cylind er, a
quantity of fluid will be drawn from th e st rut, thi s mu st be
Wylie Wet Strut (Fig. 3-14 )
discard ed together with the fluid remainin g in th e strut.
D. Thoroug hly clean th e strut outer tub e and flush out Remova l
with suitable cleani ng fluid .
A. Using Tool No. AU156A remove th e locking
Installation rin g/ gland nut from th e strut.
A. Remove the gland nut , '0 ' rin g and strut rod guide B. Remove all components retained by locking
and seal asse mbly from th e repl acemen t wet strut rin g/ gland nut.
kit. The strut rod should not be removed from th e NOTE: Wh en withdrawing th e cylind er and sleeve a
cylinder. quant ity of fluid will be drawn from th e strut , thi s must be
B. Ensure that the foot va lve is fitted squarely on th e di sca rded together with th e fluid remainin g in th e strut.
cy lin der. C. Th oroughly c lean interior of strut ou ter tube with
C. Pl ace th e cylinder compl ete with foot valve into suitabl e c leani ng flui d and d ry off.
th e outer tube of the strut.
D. Pu sh th e strut rod half way down the cylinder, pour Installation
350 ml of shock absorber oi l, part no. VS14443 A. Pour approximately 200 ml of shock absorbe r oi l
(G MH spec ifi ca ti on HN 1582), into the cyl ind er part no . VS14444 (G MH speci fication HN 1588)
and all ow it to overfl ow into the strut tub e. into th e strut tub e.
E. Install th e strut rod guide and seal over the strut B. Rem ove th e se rvice kit wet strut from th e sea led
rod. plasti c envelope.
F. Prim e th e strut by holding down th e strut rod guide C. Place the serv ice kit in the strut tube and work
and slowly moving th e strut rod up and down at strut rod up and down until an even resistance is
leas t six times with long strokes. felt.
G. With th e st rut rod in an exte nd ed pos iti on, fit th e D. Lift th e se rvi ce kit partially out of th e ca rri er tube
'0' ring and gland nut and tighten nut to 81- and add oil to bring th e total quantity to 350 mi.
108 Nm using Tool No. AU156 togethe r with a F. Reinstall the se rvice kit , in stall '0' rin g sea l and fit
tens ion wrench. lock ing ring gland nut assembly .
G. Using Too l No. AU156A tighten loc kin g rin g / gland In sta ll three se lf locking retaining nuts and wa shers and
nut to 1 22 - 135 Nm . tighten to 20-25 Nm .
H. Work th e strut rod up and down to ensure th e unit In stall the lower control arm ball joint stud to th e stee ring
is fully primed. knuckl e and tighten the castellated attaching nut to 80-
6. In stall th e boo t, and bumper on th e strut shaft. 95 Nm . Install a new split pin .
7. In sta ll the ins ul ator and upper spring seat so that th e In stall the tie rod ball joint stud to th e stee ring knu ck le and
notch in th e upper fl ange on th e sp rin g seat is in lin e ti ght en cas tellated nut to 72-90 Nm , install a new sp lit pin.
with th e wheel spindl e. Fig . 3-8. In stall th e stabilizer link stud plates, and insulators. Tighten
8. Pos iti on the ball bearing sea lin g plate wi th th e edge self locking nuts to 12-16 Nm .
pointing upward, refer arrow 'A' Fig . 3-9. Lubri ca te th e
upper support bearing with wh eel bea ring grease to
GMH spec ifi ca ti on HN 1227 and in stall th e upper CONTROL ARM
bea ring support plate and bearing assem bly .
REMOVAL
NOTE: Th e assembly mu st not be disman tl ed.
9. In stall shim and self loc kin g nut. Refer 'B ' Fi g. 3-9. Loosen the front road wheel attaching nuts. Raise front of
vehicle und er the crossmember and place safety stands
Using strut rod nut wrench too l No. AU 15 7 togeth er
un de r the side members. Refer to jacking precautions at
with a 'unive rsa l' torqu e wrench to ti ghten nut to 60-
th e fron t of this secti on.
85 Nm .
Rem ove th e front road wheels .
Remove th e stabi lizer link stud from th e control arm.
Remove the control arm inner pivot bolt and the nut
sec uring th e tension rod to the co ntrol arm. Refer Fig. 3- 1.
Remove th e ball joint stud from th e steering knuckle using
Too l No. AU152 (F ig . 3-15) and remove the control arm
G L AND NUT AND from th e veh icle.
SEAL ASSEMBLY
WET STRUT
Figure 3-15
Removing Ball Joint Stud
INSTALLING CONTROL ARM

In stall the ball joint stud in th e steering knuckle and tighten
cas tellated nut to 80-95 Nm . Install a new split pin.
Figure 3-14
In stall the tension rod to the contro l arm with the convex
Wylie Wet Strut
side of the washers toward s the bushing. In sta ll th e nut. Do
not tighten at this stage .
Install th e control arm inner pivot to front c rossmember bolt
FRONT STRUT ASSEMBLY from the- front of the vehicle.
Tighten th e tension rod nut to 95-11 0 Nm and th e con trol
Installation arm inner pivot bolt nut to 95-11 0 Nm with vehicle at curb
Make sure the mating fa ces of th e strut and spring st rut load.
tower are clean. Install th e stab iliz er link stud , plates, and insulators. Tighten
Assemble th e strut to the sp ring strut towe r mounting, lining sel f locking nut to 1 2-16 Nm.
up th e marks obse rved during disassemb ly. Re fer ln stcll road whee l and tighten attaching nuts to
Fig . 3- 1 2. speci fi ca ti on, refer Wheel and Tyre sect ion in this Manual.
TO REPLACE TENSION ROD BUSHING IN

CONTROL ARM
Rem ove th e co ntrol arm as previously outlined. Press out
the front tension rod tJusn;ng from the control arm using
Tool No. KM158-2 and AU158 as shown in Fig . 3-16.
Press in a new tension rod bushing using Tool No. AU158 ,
AU159 and KM158-2 as shown in Fig. 3-17 to assist in
installation, dip the bush in a soapy water solution. Install TOOL No. AU158
bushing with the larger diameter of the stepped tension rod
mounting hole toward s the rear of the vehic le.
TOOL No . AU159
TOOL No. AU158
TOOL No. KM158-2
Figure 3-17
Installing Tension Rod Bushing In Control Arm
(-
TOOL No. KM 158-2
Figure 3-16
Removing Tension Rod Bushing From Control Arm
TO REPLACE TENSION ROD BUSHING IN

CROSSMEMBER ASSEMBLY
Remove the control arm as previously outlined, with the
exce pti on of th e ball joint stud which remains on the
steering knuckle. Remove the tension rod from the bushing
at th e crossmember. Install Tool No . AU160 as showri in
Fig. 3- 18 and remove bushing .
Use Tool No. AU160 to draw new bushing into position as
shown in Fig. 3-1 9. The bushing is installed with the larger Figure 3-18
sho ulder towa rd s the front of the vehicle . Removing Rod Bushing From Front Crossmember
NOTE: To prevent th e bush cocking during installation , the
larger sleeve 'Too l No. AU160-1' can be placed over the
bushing in a similar manner to that shown in Fig. 3-1 8, so
that the bush is drawn through the sleeve.
Install tension rod to crossmember end, assembling NOTE: The tension rod must be installed with the longer
washers as shown in Fig. 3-1. Tighten nut to 95-11 0 Nm . shou ldered end (76 mm) in the crossmember bushing and
the shorter end (56 mm) in th e control arm bushing.
Install the co ntrol arm as previously outlined in thi s secti on.
KM-157/2
AU160
AU109
AU160-1
Figure 3-21
Figure 3-19
Install Control Arm Inner Pivot Bushing
Installing Tension Rod Bushing in Front Crossmember
LOWER CONTROL ARM BALL JOINT
INSPECTION
The control arm ball joint is spring loaded in its socket. This
compensates for normal wear. If the stud has any per-
TO REPLACE CONTROL ARM INNER PIVOT ceptible movement, the ball joint should be replaced.
BUSHING
The following procedure should be used when checking the
Remove th e co ntrol arm as previously outlin ed . Use Tool ball joint for wear.
No. AU1 62, AU1 09, and AU1 60 -1 . To remove pivot
1. Jack up the vehicle under the crossmember.
bu shin g as shown in Fi g. 3-20.
2. Remove all play from the front wheel bearings.
In stall a new bushing from th e sid e of th e control arm using 3. Holding the road wheel at the top and bottom, check
Too l Nos. AU 109, AU 160-1 and KM 157 / 2 as shown in for play in the ball joint by rocking the wheel.
Fi g. 3- 21 . 4. Readjust the front wheel bearings as described in
Th e bushing shoul d be in stall ed in a dry conditi on. Do not 'Wheel Bearing Adjustment' in this Section .
lubri cate .
TO REPLACE
1. Loosen the front road wheel attaching nuts. Rai se the
front of the vehicle under the crossmember and place
AU162 safety stands under the sidemembers.
2. Remove the front road wheel.
AU109
3. Remove the stabilizer link upper nut, bush and washer.
AU160- I 4. Remove the split pin from the ball joint stud and re-
move castellated nut.
5. Install the ball joint stud remover tool No. AU 152 from
the front side of the crossmember and free the ball
joint stud from the taper in the steering knuckle, refer
Fig. 3-1 0. It may be necessary to tap th e pivot arm on
the remover tool to assist in releasing th e stu d from th e
taper.
6. Using a suitable lever between th e con trol arm and th e
steering knuckle, prise the ball joint stud away from the
steering knuckle.
7. Swing the strut assembly free of the lower support arm
and hold out of the way with a piece of wire.
8. Remove the ball joint from the control arm , by placing
the receiving sleeve 'Tool No . AU153 ' under th e
Figure 3-20 control arm directly over the ba ll joint and supporting
Removing Control Arm Inner Pivot Bushing the sleeve and control arm on a garage jack.
9. Use Too l No. 6A28 together with a suitabl e hammer to

drive the ball joint from the con trol arm .
10. Posi ti on a new ball joint assemb ly in the lower con trol
arm .
IMPORTANT: Wh enever a ball joint has been removed from
th e con trol arm the service replacem ent .2032 mm
(.008 in .) ove rsiz e assembly mu st be fitt ed. For iden -
tification purposes , a groove is mac hined in th e larg er
diameter of the housing. If it is necessa ry to replace th e ball
joint a second time a new con tro l arm with fa ctory instal led
ba ll joint must be used.
11 . Remove the grease nipple from the replacement ball
joint.
TOOL No. AU153
12. Using ball clamp too l No . J9519-1 (sa me as 3A8-1)
together with adapter tool No. AU154 and receiving
sleeve tool No . AU 153, turn th e forcing sc rew until th e
ball joint is seated in the co ntrol arm (F ig. 3-22).
13. In stall th e ball joint stud in the stee rin g kn uc kl e and
ti ghten th e cas tellated nut to 80-95 Nm . In stall a new
sp lit pin .
14 . In stall th e stabilizer link stud , plates and insulators.
Tighten th e sel f locking nut to 12-16 Nm .
15. In stall road wheel and tighten attach in g nuts to
speci fi ca ti on, refer Wheel and Tyre Section in thi s
Manua l.
FRONT CROSSMEMBER
RE MOVAL
Remove th e co ntrol arms as previo usly ou tlin ed, with th e
exception of th e ball joint studs which remain on th e
steering knuckle .
Remove the tension rod nuts and tension rods from th e
crossmembe r.
Remove the stabiliz er bar as previo usly ou tlin ed .
Support the engi ne on a sui table liftin g hook and remove
the engi ne mounts to crossmember bol ts.
TOOL N o. J9519-1
Support th e crossmember on a jack and remove th e four (S AME A S 3A8-1)
bolts and nuts sec uring th e c ross member to th e side
membe rs.
Remove the crossmember from th e ve hi cle .
INSTALLATION
Reverse the removal operations.
Tighten the crossmem ber to side member attaching bolts
to 56-75 Nm and the engine to c rossmember mountin g Figure 3-22
bolts to 18-24 Nm . Installing Ball Joint Assembly To Control Arm.
SPECIAL TOOLS
A U1 48
J95 19-1 A U154
AU1 62
I
KM1 57-2
9A10
K M 158 -2
'----
(j r
T OOL NO . N AM E TOO L NO. NAME
AU148 FRONT COl L SPRING COMPRESSOR LOWER CONTROL ARM TENSION ROD BUSH,
A U 159 REPLACER SLEEVE (USE WITH AU158 &
AU152 BALL JOINT STUD REMOVER
KM158-2)
AU156 STRUT GLAND NUT WRENCH (ARMSTRONG) CROSSMEMBER TENSION ROD BUSH REM &
AU156A STRUT GLAND NUT WRENCH (WYLIE) AU160 INST, COMPRISING AU160-1, AU160-2 , AU160-3,
AU160-4
J95 19-1
(Same as LOWER CONTROL AR M I NN ER PIVOT BUSH
BALL JOINT INSTALLING CLAMP
3A8 -1) AU162 RE M MANDREL (USE WITH A U1 09, A U 160-1
&K M 157-2)
BALL JO I NT REM & INST RECE IV I NG SL EEVE
A U1 53 LOWER CO NTRO L A RM BUSHIN G RE M & I NST
(USE WI TH AU 154 FOR INSTAL'G BA LL JOINT) A U1 09
SPACER (USE WITH AU 160-1, K M1 57-2, A U1 62)
BALL JO INT IN STA L LER ADAPT OR (USE WI T H LOWE R CONTR OL AR M BUSHI NG INSTALLER
A U1 54
AU153) KM157 -2
(USE WI TH A U1 09 & AU 160-1)
AU 157 STRUT ROD NUT WRE NCH L OWER CONTROL ARM TE NSI ON ROD BUSH
LO WER CON T ROL AR M TE NSION ROD BUSH K M 158-2 IN ST SUPPORT SL EE V E (USE WITH AU158 &
A U1 58 RE M & IN ST M A N DREL ( USE WI TH AU159 & AU1 59)
K M1 58-2 9A 10 TIE ROD BALL JO INT STUD RE M OVER
SPECIFICATIONS
DescriptiOn .............................. .. ....................... ....... .. ................. . Mac Pherson Strut

Wheel Bearings
Type ........ Taper Roller
Lubricant ...................... Grease to G MH Spec ifi ca tion HN1227
Ball Joints
Lubricant ..... Grease to GMH Spec ifi ca tion 9985038
FRONT SPRING DETAILS
HEIGHT PROD .
TOTAL SPRING OUTSIDE
GAUGE ACTIVE IDENT.CODE
MODELS NO. OF WORKING @ RATE DIAM .
(mm) COILS (TAG ON
COILS (mm) NEWTONS (N/mm) (mm)
SPRING)
L6-8VX Models and

All other L6 Models 13.82 6 4.5 188.75 4180 26 165 VB
with Air Conditioning
All L6 Models
13.5 6 4.5 188.75 3860 26 165 VA
without Air Conditioning
V8-8VX Models and

All other V8 Models 14.20 6 4.5 188 .75 4670 30 165 VD
with Air Conditioning
All V8 Models Except

8VX without 14.03 5.9 4.4 188.75 4390 30 165 vc
Air Conditioning
Shock Absorbers
Type ....................... . .............. .. .. ..................................... Shock Absorbing Wet St rut
Make ................. ................ ... .......... ...... .. Armstrong or Wylie
Shock Absorber Oil
Armstrong ............. .. P / N VS 14443 (GMH Specification HN 1582)
Wylie ................ . ..................... P/ N VS14444 (GMH Specification HN1584)
Capacity .. .................................... 350 millilitres
TORQUE WRENCH SPECIFICATIONS

Nm Nm
Upper support bearing to spring Frt crossmember to sidemember attach. bolts ........ 40 -55
strut tower nuts ......................... ................... .. .... 20-25 Ball joint stud attaching nut .......................................... 80-95
Wet strut rod shaft to upper bearing ......................... 60-85 Control arm inner pivot bolt .... .......................... .. .. 95-11 0
Wet strut rod gland nut - Wylie ............. .. ... 122- 135 Steering tie rod ball joint stud nut ...... 72-90
Wet strut rod gland nut - Armstrong ....... 81 -1 08 Stabilizer bar link stud nuts............... ... .. .. 12-16
Ten sion rod attaching nuts ............... .. 95-11 0 Stabilizer bar bracket bolts ............. 20 -25
REAR SUSPENSION, REAR AXLES & PROPELLER SHAFT 04-01
SECTION 04
REAR SUSPENSION, REAR AXLES AND PROPELLER SHAFT
Subject Page
REAR SUSPENSION ........................................................ 04-01
REAR AXLES .................................................................... 04-11
PROPELLER SHAFT ASSEMBLY ................................. 04-21
REAR SUSPENSION
INDEX
S u~ ect Pag e Subj ect Page
GENERAL DESCRIPTION ............................................... 04-01 UPPER CONTROL ARM BUSHINGS-REPLACE ........ 04-05
SERVICE OPERATIONS ................................................. 04-03 REMOVAL .................................................................. 04-05
SUSPENSION HEIGHT CHECK ..................................... 04-03 INSTALLATION .......................................................... 04-05
COIL SPRING .................................................................... 04-03 REAR SHOCK ABSORBERS ......................................... 04-05
REMOVAL .................................................................. 04-03 REMOVAL .................................................................. 04-05
INSTALLATION .......................................................... 04-03 INSTALLATION ............................................. ............. 04-07
LOWER CONTROL ARM ................................................ 04-03 SUPERLIFT SHOCK ABSORBERS ....................... 04-07
REMOVAL .................................................................. 04-03 PANHARD ROD ................................................................ 04-07
LOWER CONTROL ARM BUSHINGS-REPLACE ....... 04-03 BUSHING REPLACEMENT ...................................... 04-07
FRONT BUSHING ...................................................... 04-03 INSTALLATION .......................................................... 04-07
Removal .............................................................. 04-03 STABILIZER BAR ............................................................. 04-07
Installation .......................................................... 04-04 REMOVAL .................................................................. 04-07
REAR BUSHING ........................................................ 04-04 INSTALLATION .......................................................... 04-07
Remova l .............................................................. 04-04 SPECIAL TOOLS .............................................................. 04- 09
Installation .......................................................... 04-04 SPECIFICATIONS ............................................................. 04-1 0
UPPER CONTROL ARM ................................................. 04-05 TORQUE WRENCH SPECIFICATIONS ........................ 04-10
REMOVAL .................................................................. 04-05
INSTALLATION .................................................. ........ 04-05
GENERAL DESCRIPTION
Th e rear suspension (Fig . 4-1) is a five link type with duces the possibility of damage to the fu el tank in th e event
prog ress ive rate rear springs. of a rear end co lli sion.
Fo r and aft movement of th e axle is co ntrolled by the upper A decoupled type stabilizer ba r is attached to the rea r ax le
and lower con trol arms while side movement is con troll ed by two brac kets and insulating bushes, th e outer end s are
by a panhard rod . The co ntrol arm s and panhard rod are attached to brackets on each sid e of th e underbody by
attached to their respec ti ve mounting points through con nectin g links and in sulating bushes.
ru bber bushes. The pan hard rod at th e ax le attachmen t has Double acting shock absorbers are mounted vertica ll y
a bell shaped washer to cover th e attaching bolt, thi s re - betwee n th e und erbody and axle housing.
0
~
I
0
1\)
PANHARD ROD J:J

m
)>
J:J
CJ)
cCJ)
"C
m
z
CJ)
BOLT & 0
BOLT ASSEMBLED FROM ~
EI THER DIRECTION
BO TH SIDES J:J
1 m
)>
J:J
)>
REAR SH OCK ......_______ ><
r
ABSO R BER m
CJ)
~ ' fl; UPPE R
BU M PE R -RE AR AX LE
Qo
---- . ll.;y ,_ ' I
' ~(( '-k
~~~~~t~
REAR SPR I NG
"'
. '. _- - - ~ &
BOLT
I
I NSULAT I NG RING
LOWER
WASHER
\ NUT ffi LOWER CONTROL ARM
VIEW [8]
£ 95-110Nm
ffi 54- 70 Nm
Figure 4-1
Rear Suspension Assembly
SERVICE OPERATIONS
Perod ic maintenan ce and adj ustm ents are not req uired for
4. Continu e to raise th e co ntrol arm far enough to install
th e rear suspensio n compon ents. Th e suspe nsion sys tem
th e lower con trol arm attac hin g bo lt to the axle end . Do
should be c hecked for shock absorbe r acti on, co ndi ti on of
not fully tighten nut at thi s stage.
suspension bushing s, tigh tn ess of suspension attach ing
bo lt s and an ove rall vis ual inspecti on of co mponents for 5. In stall th e rear wheel and tighten wh eel nu ts to
defec ts. Specification refer wheel and lyre secti on in th is
Manual.
SUSPENSION HEIGHT CHECK 6. Remove th e garage jack, raise th e rear axle, remove
th e safety stands and lower th e vehicle .
For suspension heig ht c hec king dimensions, refer to th e
7. Tighten the nut on th e con trol arm attaching bolt to
front suspension section und er headi ng 'Suspension
95-11 0 Nm with th e vehicle on th e floor and at kerb
Heig ht Check '.
load .
COIL SPRING
REMOVAL LOWER CONTROL ARM
For id entifi ca ti on of parts refer (Fig . 4- 1).
REMOVAL
1. Raise vehic le and support on safety stand s und er the
rear jacking point s. Refer Fi g. 1- 1 Body Secti on for 1. Carry out steps 1 to 5 as prev iously described for co il
locati on of jac kin g poin ts. spring removal.
2. Remove the rear wh eel. 2. Rem ove the lower co ntrol arm attaching bracket and
rem ove the co ntrol arm from th e vehicle .
3. Place a portab le ga rage jack under th e lower co ntrol
arm d irectl y beneath th e sprin g (Fig. 4-2)
INSTALLATION
4. Raise th e jack fa r eno ugh to all ow remova l of th e lowe r
1. Insta ll the lower co ntrol arm and attaching bolt to the
co ntrol arm attach in g bolt from th e ax le end .
body attaching brac ket. Do not full y ti gh ten nut at thi s
5. Gently lower th e jack far enough to remove th e sp rin g stage .
togeth er with th e upp er and lower insu lating rin gs.
2. Carry out steps 1 to 7 as prev iously describ ed for coi l
spring insta ll ati on.
INSTALLATION NOTE: Th e nuts on both front and rea r co ntrol arm at-
1. Posi tion th e rubb er insulators on eac h end of sp rin g. tachin g bol ts are tight ened to 95-11 0 Nm .
2. Install th e spring in pos ition on th e lower co ntrol arm
seat with th e tapered coi ls to th e top .
3. Raise th e co ntrol arm sli ghtly and posi ti on th e spring LOWER CONTROL ARM BUSHINGS -
in th e upper seat on th e und erb ody. REPLACE
FRONT BUSHING
Removal
Wi th the lower co ntrol arm rem oved from th e vehicle, press
out the front bu shing using Tool No. KM 37 1/ 4, KM 37 1/ 5
and KM 372 / 4 as shown in (F ig. 4-3) .

Rear Spring Removal Removing Lower Control Arm Front Bushing
04-04 REAR SUSPENSION, REAR AXLES & PROPELLER SHAFT
Installation
In stall front bushing using Tool No. KM 371 / 4, KM 371 / 6
and KM 372 / 4 as shown in (Fig . 4-4).
Th e bushing is ste pped and can only be installed one way.
Before pressing the bushing into the control arm, ensu re
that it is co rrec tl y positioned as shown in (Fig . 4-5).
REAR BUSHING
Removal
With the lower control arm removed from the vehicle , press
the rear bushing from th e axle housing using Tool
No. KM 372 / 3, KM 372 / 4 and KM 372 / 5 as shown in
(Fig. 4-6).
Installation
Install th e bushin g in the axle housing from th e notched
sid e of th e bracket and alig n notch with paint stripe on Figure 4-6
bushin g. With th e bu sh correc tl y installed, th e off -set centre
Removi ng Lower Control Arm Rear Bushing
sleeve in th e bush is located as shown in (F ig. 4- 7).
Install th e bushing usin g Too l No. KM 372 / 1, KM 372/ 2

and KM 372 / 3 as shown in (Fig. 4-8).
KM - 371 /6
Figure 4-7
Rear Bushing Correctly Positioned in Axle Bracket
Figure 4-4
Installing Lower Control Arm Front Bushing

Front Bushing Correctly Positioned in Contro l Arm Installing Rear Bushing
UPPER CONTROL ARM
REMOVAL
Raise the veh1cle and support on safety stands under the
jacking points. Refer Body Section for location of jacking
points.
Place a garage jack under the rear axle housing and raise
far enough to remove spring load from upper control arm.
Remove bolts from attachment points on underbody and
axle housing, and remove control arm from vehicle.
INSTALLATION
Install the upper control arms with the flanges in the pre-
ssing towards the outside of the vehicle.
Install attaching bolts. Do not tighten at this stage.
Remove the safety stands, and lower the vehicle. Tighten
the nuts on the control arm attaching bolts to 95-11 0 Nm
with the vehicle on the floor and at kerb load.
Figure 4-10
Installing Upper Control Arm Bushing
UPPER CONTROL ARM BUSHINGS -

REPLACE
REMOVAL b}-CAP
With the upper control arm removed from the vehicle press I
®-~---
NUT 1
L..!..:;
out the bushings using Tool No. KM 371/1 and KM 371/2
® -- - - PLATE
as shown in (Fig . 4-9).
@ - ---- BUSH
INSTALLATION
Install bushings using Tool No. KM 371 / 1 and KM 371/3 6-.::L_
r~~p
as shown in (Fig . 4-1 0).
I I
L __ j_)
KM-371/1
54-70 Nm
12-~6Nm
Figure 4-11
Rear Shock Absorber Mountings
Figure 4-9
Removing Upper Control Arm Bushing
Open the rear compartment lid and prise off the protective
caps from the upper shock absorber mounting from inside
the rear compartment. (Fig. 4-11 ).
REAR SHOCK ABSORBERS Disconnect the shock absorber at the upper mounting by
removing the nut, retainer washer and grommet.
REMOVAL Disconnect the lower mounting by removing the retaining
Raise rear of vehicle and support rear axle assembly on bolt and nut from the mounting bracket on the rear axle
safety stands. housing .
-
"
-\\
-.._
·.
~
.,
-
'
\.,.·'
-·y ~
.
J;;
~
'l.~ .
~------
'
I'.
0
~
I
0
0')
JJ
_) ·~~··· m
:J>
JJ
r - -p::SSURE LINE- /~- V.IEW [ g
CJ)
cCJ)
.,
I
/'
':?-==----;~
PRESSURE LINE \
... ·---- [A].

I
I
.
J. " \J m
z
CJ)
0
~ - ~~~~
1 . t .· - -ce:- -··-:~
- 1il~-~ v_A_
">-// ,-~
~
VIEW IQ] ----- "'~~~ JJ
~
·- ~" ~... -./~\ m
J/ -,
~
J /~:.~ ~ ~ :J>
~~ [QJ~~- ~,\lA
.. "!(.0} '. JJ
~~~p
( I
/\' ~~
• :J>
~-~ !-~ ~
/
~
~~ ><
--------~---IJ·
-
HOCK
7
!:.!;0 • '.• /r-- ,,_fcD\
·1 ( @''\1.\.v-j
' I
r
1/-/ / m
!ssoRBER ' ' /
\
i I
V IE wiFI CJ)
~ .,
-~~-
-, ~~'l5'
Qo
/ ICl
w ' -=- ( '
\'-.'."',
< ::':'5-t:--. ;t
L . \...
VIEW [g) ~CAP JJ
.,m0
'Q
··'->f
ff~ CORE ASM .
~-
r r
~!
/~ '\') #
- VALVE-
r
m
::._ / .----- NUT - JJ
/ - WASHER
I - LABEL -
~L I BODY-VALVE ..!
- J
'-J rA1
[g]
SECTION A-A VIEWt& VIE W
Fi gure 4-12
Superlift Shock Absorber Inst allation
INSTALLATION
Before installati on c hec k th e shock abso rb er acti on and
inspect rubb er bushings, repl ace wh ere necessary .
To instal l th e shoc k absorber, reve rse th e removal op -
erat ions. Ti ghten th e upper attac hing nut to 1 2-16 Nm and
th e lowe r attac hing bolt and nut to 54 -70 Nm .
SUPERLIFT SHOCK ABSORBERS

Rea r superlift shock abso rb ers are available as opti onal
eq uipm ent. The superlift system (Fig . 4-1 2) is an assis t
type levelling device which is set manua ll y by varying th e
ai r pressure in th e system. Air pressure is adj usted by
means of a lyre- type va lve co nven iently located in th e rear
co mpartment. Sin ce th e one va lve se rves both units, ai r
pressure is equal at all tim es.
To ensure sa tifactory fun cti onin g of th e superlift system,
observe th e foll owing preca uti ons:
a. Maintain a minimum of 69 kpa (1 0 PSI ) for best
ride c haracteri sti cs with an empty ca r.
b. Maxim um permi ss ibl e press ure wi th ve hi c le un - Figure 4-14
laden is 448 kpa (65 PSI). Installing Bushing in Panhard Rod
c. Vary press ure up to a maximum of 621 kpa
(90 PSI) to level th e ca r with loads.
PANHARD ROD
STABILIZER BAR
REMOVAL
Remove th e nut and tan k protector wa sher from th e REMOVAL
mounting on th e rea r ax le and th e nut and bolt from th e
For id entifi ca ti on of parts refer Fig. 4-1 5.
body mounting .
Rai se th e rea r of the vehi c le and support th e rear axle on
BUSHING REPLACEMENT safety stan ds.
Press bushings out of pan hard rod usi ng Too l No.A U 105 Di sco nn ect the stabi li zer spacer stud s at the brackets on
together with a sutabl e press plate (F ig . 4- 13) eac h side of the body.
Press bushings and space r sleeves in to panh ard rod by Rem ove the stabi lizer bar bracket retaining bolts and nuts
hand as shown in (Fig. 4-14) . Use white spirit as a on eac h side of the ax le housing and remove th e brackets
lubricant. and in sulators.
Remove the stabiliz er bar from the vehic le.
INSTALLATION In spect th e rubber in sul ators and bushes and rep lace
Install panh ard rod as reve rse to remova l proced ures. wh ere necessary.
Tighten th e axle housing attac hin g nut to 54 - 70 Nm and
the body attaching nut to 95- 11 0 Nm . INSTALLATION
In stall th e stabili ze r bar as reve rse to removal operations.
Ti ghten th e bracke t retaining bol ts to 14-1 8 Nm and the
space r stud nuts to 12-16 Nm .
Figure 4-13
Rem oving Bushing From Panhard Rod
E zE
z
co <D
a:
<{
OJ
a:
w
N
_J
OJ
<{
f-
C/l
iii
ID
--~ L()
,....
....
Q)
~ ~
\ Q)
.... ·-
.c
:::l <0
.2l
u..
iii....
a: <0
0 f-
f- w Q)
a:
<{ ~
_J u
:J <{
(/) a:
z OJ
I
(/)
:J
(IJ
SPECIAL TOOLS
KM371 -6 \
KM371 CONTROL ARM BUSHING REMOVING

AND INSTALLING SET.
KM371 -5
KM372 LOWER CONTROL ARM REAR

BUSHING REMOVING AND
INSTALLING SET.
AU105 PANHARD ROD BUSH REMOVER AU105

MANDREL (USE WITH SUITABLE
PRESS PLATE) .
SPECIFICATIONS
Type an d Descri pti on ........... Rigid Axle, 4 Trailing Arm s and Panhard Rod
Drive and To rq ue ..................... ... ........ .. .............. ..... Taken Through Tra iling Arm s
Co il Springs
Free Heig ht 420 mm
In side Di ameter ..... ...................... .. ....... ............. ..... ........ ......... 94 mm
Gauge ....................................................................... ................ Tape red Wire
Sta bilizer Ba r ...................... ........... Li nk Type wi th Rubb er Insulated Bu shing s
Rear Shock Abso rb ers .............................. .. ....................... Twin Tube Telescopic
Nm
* Lower Co nt ro l arm atta c hings bo lts .... .. ..... .. ..... 95 - 11 0
* Upper Control arm attac hin gs bo lts ...................... 95 - 11 0
Stab ili ze r bar brac ket attac hings bo lts .. .. .......... 14 - 18
Stabili zer bar space r stud nuts ........ ........................... 1 2- 16
''' Pan ha rd rod attac hing nuts to ax le ho usin g .......... 54 -70
''' Pan hard rod atta c hin g nuts to body mountin g ... 95 - 11 0
Shock abso rb er upper mountin g nut ......................... 1 2- 16
Shoc k abso rb er lower mountin g nut ...... ................... .. 54-70
NOTE: • To rqu e with vehi c le on th e floo r at ke rb load.
L
REAR AXLES
INDEX
Subj ec t Page Subject Page
GENERAL DESCRIPTION ............................................... 04-11 DIFFERENTIAL CASE .............................................. 04-14
REAR AXLE USAGE CHART ........................................ 04- 11 Disassembly ....................................................... 04-14
SERVICE INFORMATION FOR STANDARD Inspection ........................................................... 04-14
REAR AXLE ...................................................................... 04-13 Reassembly ........................................................ 04-14
PERIODIC SERVICE ................................................. 04-13 Pinion and / or Bearing Replacement ............ 04-14
AXLE SHAFTS, BEARINGS & SEALS ................. 04-13 Pinion Bearing Preload & Pinion
PINION OIL SEAL & REAR UNIVERSAL Location .............................................................. 04-15
JOINT FLANGE REPLACEMENT ............................ 04-13 To Determine Pinion Location ....................... 04-15
MAJOR SERVICE OPERATIONS ........................ .......... 04-13 Pinion Installation ............................................. 04-16
REAR AXLE HOUSING ASSEMBLY ............................ 04-13 Differential Bearing Preload &
REMOVAL .................................................................. 04-13 Ring Gear Adjustment ..................................... 04-17
INSTALLATION ........................ .................. ...... ......... . 04-13 Ring Gear & Pinion Contact Pattern ............ 04-18
REAR AXLE OVERHAUL ............................................... 04-13 SPECIFICATIONS ............................................................. 04-19
DISASSEMBLY .......................................................... 04-13 TORQUE WRENCH SPECIFICATIONS ........................ 04-19
SPECIAL TOOLS .............................................................. 04-19
GENERAL DESCRIPTION
Th ere are two different size salisbury type rear axle rear axle section of the HO Service Manual, Volume 3, Part
assemb li es used in th e VB Se ri es. Number M37017 to service this axle.
1. A sa li sb ury type ax le with 178 mm diameter rin g gear 2. The heavy duty axle assembly option G73 with the
ref er (Fig . 4- 15A) is used as standa rd eq uipm ent on 190 mm diameter ring gear and limited slip dif-
all mode ls except th ose with th e 5 li tre engine. (Refer ferential, is available on all models and is mandatory
to th e rea r axle usage chart in thi s section for furth er when the 5 litre engine is used. This axle shares many
details of ax le and ratio usage). common parts with the current Holden heavy duty axle.
Th e standa rd ax le has many parts identical to th ose used Servicing and overhaul information is available in the
in th e banj o type ax les fitt ed to prev ious Holden Models. HQ Holden Service Manual , Volume 3, Part
No . M37017.
Th e se rvic ing and overh aul inform ati on that foll ows in th is
secti on shou ld be used in co njun cti on with th e Banj o type
REAR AXLE USAGE CHART
MODEL
OPT I ON AVAILABLE
8 8 8
RA TI O: 1 STAND ARD OR
CODE
H EAVY DUTY
v v v
K L X
G70 2.6 Heavy Duty On l y 0 0 0

On l y w ith 5 li tre engi ne
GU 4 3.08 Standa rd, or 0 B 0
Heavy Duty 0 0 0
GU7 2.78 Standard 0 0 B
GV4 3.36 Standard, or 0 0 0

Heavy Duty 0 0 0
GV7 3.55
Standard, or Heavy Duty B 0 0
REFER TO TRANSMISSION SECTION OF POWER TRAIN COMB IN ATIONS
0 - Opt i ona l
B - Base Equipment
" ' " " "m' """ '"'"'"' joio<-~
F lan ge-re tainin g nut
F lange & du st seal asrn: - Cone- rear ax le pin front bea ring
Cup- rear ax le pin front bea ring
Figure 4-15A
Section View of 178mm Salisbury Type Rear Ax le
REAR SUSPENSION, REAR AXLES & PROPELLER SHAFf 04-13
SERVICE INFORMATION FOR STANDARD

REAR AXLE
PERIODIC SERVICE
Periodic se rvice is th e same as for the ban jo type rear axle.
AXLE SHAFTS , BEARINGS AND SEALS

The rear axle shaft beari ngs and sea ls ca rry over from the
Holden Series. Se rvi cing and ove rhaul procedures are the
same as shown in th e HQ Holden Se rvice Manual ,
Volume 3, Part Number M37017 .
PINION OIL SEAL AND REAR UNIVERSAL JOINT

FLANGE REPLACEMENT
Proced ures are th e same as shown in th e HQ Hold en
Service Man ual , Part Num be r M370 1 7.
Figure 4-16
Checking Ring Gear Backlash

REAR AXLE HOUSING ASSEMBLY REAR AXLE OVERHAUL
REMOVAL DISASSEMBLY
For iden tification of compo nents, refer (F ig. 4-1 ). 1. Clamp rear axle assemb ly in a suitabl e holdin g fi xture.
1. Using a lifting jack und er the cen tre of th e axle, jack 2. Remove brake drums and axle shafts.
up th e rear of th e vehic le th en place stands under th e 3. Drai n lubricant from carrier by removing cover.
rear body jacking points. 4. Befo re removing th e differential from th e housing, rin g
2. Remove the rear wheels; remove propel ler shaft from gear to pini on backlash should be checked. This will
th e rea r unive rsa l joint flan ge, and unbolt ce ntre indi cate gear or bearin g wea r or an error in backlash
bea ring support. or pre-load settin g which will help in determinin g
3. Set th e pa rk brake in th e fully released positi on. Di s- cause of axle noise (Fig . 4- 16) .
co nn ect rear cab les from interm ed iate ca ble at co n-
nectors .
5. Mark one bearing cap and housin g for reassembly in
4. Remove th e rear cable to bracket ' U' clips and with - th e same position . Rem ove th e bearing cap bo lts and
draw cables. bearing caps.
5. Di sc onnect the hydraulic brake hose at the rear ax le
to brake line connection . CAUTION: Tap surface of bearing caps to loosen. Do not
6. Disconn ect th e rear shock absorbers at lower moun - attempt to pry caps off as th is may damage machined fa ce
tin g points and push up out of the way. of caps.
7. Di sconnect th e rear stabiliz er bar and the panh ard rod
at th eir lowe r links. 6. Using a suitabl e lever pri se differential assembly out
8. Support lower suspen sion arm s. of carri er taking care not to damage machin ed
9. Remove upper and lower control arm attaching bolts mounting surfaces of carri er. If the bearings are
at axle housing and remove housing from vehi c le. pre-load ed, the case will suddenly fall free th erefore
make sure it is properly supported to prevent damage.
INSTALLATION Th e bearing caps may be loosely install ed to prevent
the case from falling.
Reve rse to removal ope rati ons with atten ti on to the fol-
7. Place left and ri ght bearing cups with bearin g caps so
lowing:
that they may be re-in sta ll ed in original positi ons.
1. Ti ghten co ntrol arm and pan hard rod attaching bolts Place shim s with ap propri ate cups.
to spec ifi ca ti ons with vehicle at kerb load position .
8. Install Tool No.4A39 / 1 on flang e so th at th e four
2. Fill th e differen tial ca rri er to co rrec t level with th e notches are towa rd s flange and remove pinion flan ge
spec ifi ed gea r oil. nut and washer. Discard nut and use a new one on
3. Re-adjust brake shoes and bleed system . reassemb ly.
9. Thread pi lot end of Too l No.4A39/3 into small 0 .0 . end Reassembly

of Tool No.4A39 / 2 then with Tool No.4A39 / 1 in stall ed Before assemblin g th e differential case, lubri ca te all part s
as in step 8, insert Too l No.4A39 / 2 into Too l with th e spec ified gear lubri cant.
No.4A39 / 1 and turn it 45 deg rees to loc ked pos iti on.
Remove flange by tu rnin g Too l No.4A39 / 3 and holding 1. Place sid e gear thrust washers ove r side gear hubs
Tool No.4A39 / 1. and in stall side gears in case. If sa me parts are re-
used, in stall in original sides.
10. Pry old pi ni on shaft oi l seal out of bore using a
sc rewd river or suitabl e too l. 2. Pos iti on one pini on (with out washer) between th e sid e
gears and rotate gears until pini on is directly opposi te
11 . If deflec tor requ ires replacement, remove by tappin g from loading openin g in case. Pl ace oth er pini on be-
from flange, c lean up stake points: in stall new deflector tween sid e gears so that pini on shaft holes in pini ons
and stake at three new equ all y spaced pos iti ons. will lin e up with holes in case.
NOTE: Staking operation must be perform ed in such a 3. Wh en holes lin e up, rotate pini ons bac k towards
manner that the seal operating surface is not damaged. loadin g opening just enough to perm it in stallati on of
12. Remove drive pinion by tapping on front end wi th a soft pinio n thrust washer.
faced hammer. Then remove pinion front bearing cone 4. Install pinio n shaft and loc k pin .
from carri er bore. Disca rd pinion bearing spacer and
use a new one upon reassembly. NOTE : Install lock pin to a depth of 13 mm as shown in
(Fig. 4-17) .
DIFFERENTIAL CASE
Disassembly
1. Before dismantlin g diffe rential case, in spect dif-
fe rential side bea ring s for vi sibl e damage of rollers and
outer races .
NOTE: Both side bea rings and their outer ra ces are
matched parts. If ei th er bea ring is to be replaced , its
matchi ng oute r race must al so be replaced.
2. If bearing in spection indi ca tes that bearin gs should be
rep laced, hold di fferenti al case in a vi ce and remove
side beari ngs using a suitabl e bearing pull er. Make
sure puller legs are fi tted sec urely in notches in case
and against bea ring co ne.
3. If ring gear is to be repl aced and it is tight on case after
removing reta ini ng bolts, drive it off usin g a brass drift
and hammer. Do not pry between ring gea r and case.
4. Using a sui table punch, drive out th e pini on shaft loc k
pin. Figure 4-17
5. Drive pinion shaft out of case , using a brass drift. Differential Pinion Shaft Lock Pin Installation
6. Remove di fferential pini on gears , thru st washers and
side gears. Place th em in sets so they may be re-
5. After making certain that matin g surfaces of case and
installed in thei r ori ginal pos iti on.
ring gear are clean and free of burrs; in stall guid e pin s
made from 318 " -24x1 1/ 2" UNF bolts with heads c ut
Inspection
off and end s slotted , to ring gear. To assist fitm ent,
1. Clean all bearings and gears in an approved c leaning warm ring gear previously to approxim ately
solvent and inspect all bearing cups, ra ces and rol lers 100 degrees C (boiling water) .
fo r scoring, chipping or eviden ce of excess ive wear.
6. Assemb ly ring gear to case, and in stall every oth er rin g
On pinion bearing roll ers, in spect rollers for wear,
gear bolt, th en tigh ten th em evenly until th e gear face
particularly on the large end of th e rollers, whi ch is
is flush with face of case.
usually the first place to exhibit wear on tapered rol ler
beari ngs. 7. Remove guide pins and in stall remainin g bolts. Torqu e
all bolts even ly to 81 -92 Nm.
NOTE: Th e pi nion bearings are of the tapered type, and th e
natural wea r pattern is a frosted cond ition with occasional 8. If differential side bearing s were removed place new
slight sc ratches on races or rollers. This does not indi ca te bearing on hub wi th thick side of inn er ra ce toward
a defective bea rin g. case and press in to place using Too l No.4A25 .
2. In spect pini on spli nes and flange splines for evid ence
of wea r.
3. In spec t rin g gear and pini on teeth for signs of sco rin g,
crac kin g or chippin g. Pinion and / or Bearing Replacement
4. In spect differential case for cra cks or scores on side 1. If necessary to rep lace pinion bearin gs remove old
gears, thru st washers, and pini on thru st faces. cups from carrier using Too l No.4A 20-5 for th e front
5. Check fit of differential sid e gears in case . bearing, or Tool No.4A2 0-4 for th e rea r bea rin g to-
6. Check fit of side gears and axle shaft splin es. geth er with handle Too l No.4A20- 1 (Fi g. 4- 18).
7. Inspect differenti al pinio n shaft for sco rin g or ev idence 2. ln spec t c up seats for ni c ks or burrs and remove as
of excessive wear. necessa ry.
3. Position new bearing c up in ca rri er, th ick edge of cup

toward s should er in carri er; then , usin g c up in staller
Tool No.4A2 1-5 to install front c up and Tool
No.4A2 1-4 to in stall rea r c up togeth er with handle Tool
No.4A2 1- 1 press cup into ca rri er until it seats against
th e should er (Fig . 4- 19) .
4. Remove pini on rea r bearing co ne and roller assembly

using Too l No.4A22 (Fig. 4- 20). Reco rd thickness of
shim removed from between bearing co ne and pinion
TOOL No. 4A 22
head .
l
u
)
I
REAR PINI ON SEAR l
CONE ASSY .
Figure 4-20
Removing Pinion Rear Bearing
Figure 4-18
Pinion Bearing Pre-Load and Pinion Location
Removing Pinion Bearing Cup As normal wear takes place on the pinion bearing s, the
location of the pinion in relation to th e ring gear will differ
from its original setting , the tendency being for the pinion
to move out of mesh, this being particularly true wh en th e
pinion bearings have lost all pre-load or when end play in
the bearings has developed . With these conditions, the
pinion locating gauge set, 4A32 , is invaluabl e in de-
termining the shim stack for co rre ct location of the pini on
(Fig . 4- 21 ).
Wh en ring gear and pinion , differential carri er, or pi nion
bearings are to be replaced , the pinion locatin g gauge set,
4A32 , is an essential tool.
To Determine Pinion Location

1. Insta ll rear bearing inner cone and roll er assembly on
to dummy pinion . Lubricate th e bearings with gear oil.
2. In stall dummy pinion and rear inner cone and roller
assemb ly in ca rri er without the coll apsib le spacer.
Insta ll front inner cone and roller assembly, pulley,
washer and retaining nut.
3. Tighten retainer nut gradually while alternately turning
pinion assemb ly to settl e bearings. Attach a spring
sca le to pulley and check th e bearing pre- load .
Continue to tighten the retaining nut until th e spec ifi ed
pre-load is obtained .
NOTE: The pinion bearings should be lubri ca ted with th e
specified differential EP gear oil before in stall ati on. Do not
use engine or other oils, as a misleading scale reading can
be obtained. For used bearing s th e co rrect pre-load is
Figure 4-19 56 -90 Ncm (5-81b in) and for new bearings 135- 175 Ncm
Replacing Pinion Bearing Cup (12-15 1b in).
Figure 4-21
Assessing Pinion Locati ng Shim Stack
PINION DESIGNATION
When checking bearing pre-load, it is essential to have the ETCHED IN THIS LOCATION
pulley rotating at the correct speed to ensure accurate
readings . The correct rate of rotation is approximately
50-60 rpm. Figure 4-22
Pinion bearing prP-Ioad is very important because it retains Pinion Designation Marking
the drive pinion in its correct relationship to the ring gear.
Bearings that are installed with insufficient or no pre-load
will, after a comparatively short period of running, develop
end play, causing noisy operation on overdrive, and could
be responsible for scuffing of the ring gear and pinion teeth.
Bearings that are overloaded may become pitted or flaked
and result in ultimate failure. It is therefore essential to
ensure that the bearings are pre-loaded to the specified
torque. Pinion bearing pre-load must be established before
any attempt is made to determine the pinion locating shim
stack.
4. When the pinion bearing pre-load is correctly ad-
justed, mount the arbor in the differential carrier, side
bearin gs and check clearance between arbor and
dummy pinion with a feeler gauge. When checking
Figure 4-23
clearance , maintain hand pressure on the arbor and
oscillate in a short arc (Fig. 4-21 ). The arbor must not Relative Position of Shims
lift, but sli ght drag on the feeler must be evident.
Record thi s dimension and note etched figure marking
on the end of pinion (Fig . 4-22).
Examples: No marking or zero equals 0, minus 2 equals
Minus, plus 3 equals Plus.
Pinion Installation
1. Remove arbor, dummy pinion, etc., from the differential
For a zero pinion , the feeler gauge measurement is the shim carrier.
stack required to correctly locate the pinion: and shim, or 2. Select pinion location shim thickness determined by
shims, equivalent to this dimensi on can be selected for pinion locating gauge set and install on original or new
assembly between the rear pinion inner race and roller pinion. Then press rear inner race and ro ll er assembly
assembly, and the shoulder directly behind the pinion head against shoulder of pinion, using Tool 4A24.
(Fig. 4-23). For a minus pinion, add the numeral adjacent
to the sign to the feeler gauge measurement. For a plus
IMPORTANT: To avoid possible damage to the pinion gear
pinion, subtract the numeral adjacent to the sign from the
teeth, ensure the press plate is perfectly flat, free of burrs
feeler gauge measurement.
and foreign matter prior to bearing cone installation. Locate
NOTE: Pinion locating shims are serviced in the following the bearing cone squarely on the pinion .
thickness: 3. Install collapsible spacer on pinion and install as-
.005 in.,.006 in.,.007 in.,.008 in.,.009 in.,.01 0 in. and sembly in carrier, then install front inner race and roller
.015 in. assembly .
CAUTION: Should the retaining nut be overtightened and 5. With the case assembly held aga in st th e left hand side
pre-load exceeded, it will be necessary to remove the pi- of the differential ca rrier, select a shim that is a zero
nion from the housing and install a .020 in shim as outlined clearance fit between the ri ght hand bearin g and
in item 4 below. Under no circumstances must the retaining differential carrier.
nut be backed off to decrease the pre-load reading. 6. Measure the thickness of the shi m selected in step 5
4. Leather element type pinion shaft oil seals should be and add .254 mm to this measurement. Thi s total will
soaked in engine oil for at least one hour, then dry the be th e size of the adjusting shim used on th e righ t hand
outer shell thoroughly. Coat the outer surface of the side.
seal with non hardening gasket cement. Dual lip type 7. In stall the selected shim between the bea ring and
seals should have 500 mg. of multi purpose grease differential ca rrier by driving into position using Too l
applied between the primary and flexible wiper lips. No. AU 139 (Fig . 4-24).
5. Install seal in carrier using Tool No.4A3-C.
6. Install pinion flange, washer and retaining nut. Tighten 8. In stall righ t bea ring cap and to rque both caps to 54-
retaining nut gradually until the front pinion bearing 6 1 Nm (40- 45 lb.ft).
cone is seated against the collapsible spacer, when the 9. Mount a dial indi cator on th e ca rri er and check
end play in the pinion shaft should be approximate ly backl as h between ring gear and pi nion. Bac kl ash
.762mm. should be within th e rang e of .152 to .229mm (006 in
Attach a spring scale to the pulley and flange and check to .009 in ). Check reading at four equally spaced
the drag of the oil seal, then record the figure obtained, pos iti ons around th e ring gear. Vari ati on in reading
which must be added to the final pre-load figures of 56- shoul d not exc eed .050mm (.002 in ).
90Ncm (5-81b in) for used bearings 135-170Ncm (12- 151b
in) if new bearings have been used. NOTE: Pos iti on the dial indi cator so that indi cator button
Theoretical Example: Oil seal drag is 68Ncm (6 lb in) is perp endi cular to tooth angl e and in lin e with gear
therefore final pinion assembly pre-load figures would be ro tati on.
68Ncm (6 lb in) plus 56-90Ncm (5-81b in) equals 124-
158Ncm ( 11 -141b in) for used bearings or 68 Ncm (6 lb in) 1 0. If vari ati on in backlash exceeds .050mm (.002 in )
plus 135-169Ncm ( 12-151b in) equals 203-237 Ncm ( 18- measure rin g gear and case run out as shown in
211b in) for new bearings. Continue tighteni ng the retai nin g (Fig. 4- 25). Gea r run out should not exceed thi s limit,
-nut while alternately turning the pinion assembly to seat the chec k ring gear and case for di storti on and /o r foreign
bearings until the required pre-load figure is reached. matter between case and gear.
Further rotate the pinion an extra 30-40 turns and recheck
the pre-load to ensure that no change has occured . 11 . If gear lash is not within limits, co rrect by dec reasin g
NOTE: If the collapsible spacer has been used before, on shim thickness on one sid e and in c reas ing thi ckn ess
reassembly install a .020 in. shim in conjunction with th e of the othe r shi m th e same amount. Total shim
spacer. If on disassembly it was found that a .020 in shim th ickness must be maintain ed to maintain proper
had already been installed, on reassembly two .020 in. pre-load.
shims must be used. If the spacer has already been used
with two .020 in. shims, the spacer must be rep laced by a
new one. The flange retaining nut is of the se lf-locking type
which must be replaced with a new nut whenever th e
differential carrier assembly is overhauled.
Differential Bearing Pre-Load and Ring Gear

Adjustment
Differential side bearing pre-load is adjusted by chang in g
the thickness of both the right and left shims by an equa l
amount. By changing the thickness of both shims eq ual ly,
the original backlash will be maintained. Shims vary in
thickness from 5.65 mm to 6.55 mm in increments of
0.05 mm
1. Before installation of the case assembly, make sure
that side bearing surfaces in the carrier are c lean and
free of burrs. Side bearings must be oiled with gear
lubricant, and if the same bearings are being re- used,
they must have the original outer races in place.
2. Place differential case with bearing outer races in
position.
3. Se lect and install an adjusting shim to fit between the
left hand bea ring and differential carrier that will give
a backlash of approximately .0127 mm (.0005 in.)
between the ring gear and pinion.
4. Install th e left hand bearing cap loosely so that the Figure 4-24
case may be moved while checking the adjustment. Driving Spacer Into Position
The large end of the tooth is call ed th e 'hee l' and th e small
end , th e 'toe ', also the top of th e tooth whi ch is th e part
above the pitch line, is call ed th e 'face' whil e th e part below
the pitch line is cal led the 'flank '. Th e space betwee n th e
adjacent meshing teeth is referred to as 'bac klash'.
Figure 4-26 shows correct and in co rrect co ntact pattern s.
Contact pattern 'A' provides th e id eal bearin g for qui etn ess
and long life. If the pattern shows a toe co ntact 'B' it in -
dicates not enough backlash. To co rrect, move th e rin g
gear away from th e pini on by in creasin g ri ght shim
thickness while dec rea si ng left shim thi ckness an equal
amount.
If the pattern shown a heel con tact 'C' it indi cates too mu ch
backlash . To co re ct, move th e rin g gear toward s th e pini on
by increasing left shim thi ckness whil e dec reasin g ri ght
shim thi ckness an equal am ou nt.
NOTE : Make adjustment, in c reasing and dec reas ing shim
thi ckness by .050 mm at a tim e, chec k co ntact with gear
markin g compound and continu e adj ustm ent until tooth
·Figure 4-25 contact appears as in 'A' . Bac kl ash mu st remain within
Checking Ring Gear Run Out limits.
To correct a pattern such as '0 ' it will be necessary to
install a thicker pinion shim as desc rib ed und er 'Pini on
Ring Gear and Pinion Contact Pattern and / or Bearing Replacement. ' A .0 01 in . thi cker shim is
re co mm end ed as a sta rtin g point. Continued chang es may
1. Thoroughly c lean th e ring gear and pini on teeth . be necessary to obtain the correct setting . If th e pattern
2. Paint rin g gear teeth lightly and evenly with gear shows a flank con tact 'E', it indicates that th e pini on is in
marking co mpount of a suitabl e consis tency to pro - too far. To co rrect, replace th e pini on shim with a .00 1 in .
duce a co ntact pattern . thinn er shim and recheck contact pattern .
3. Install axle shafts and drum s, install wheel nuts to In making pini on adj ustments, be sure bac kl ash is co rrect
retain drum s on ax le shafts. Expand brake shoes until before testing contact pattern , moving th e pini on in redu ces
a torq ue of 81 Nm (60 lb.ft) is obtain ed at pinion backlash and moving it out in crea ses bac klash. After
flange. satisfactory contact pattern is produced as in 'A', c lean ring
4. Rotate pinion through seve ral revoluti ons in th e for- and pinion gear teeth and pour a liberal quantity of rear
ward and reve rse directi on until a definite con tact axle lubri cant on the gears and bearings. Turn gears to
pattern is developed on th e rin g gear. work lubri can t into all surfaces.
5. Inspect th e con tact pattern produ ced by the above Finally assemble cover to differential carri er and ti ghten
procedure. bo lts to 34-41 Nm .
TOE CO NTACT CORRECT HEEL CONTACT

TOOTH
CONTACT
~
,\ -
F A CE CO NTA CT FLANK CONTACT
Figure 4-26
Gear Tooth Contact Patterns
SPECIFICATIONS
A x le Shaft
Type . . .. .. ...... . ..... . Sem i Floating
Bearing Type . . . . . . . . . Taper Roller
Oil Sea l . ... ... .. .. . ..... Spring Loaded Synth etic Ru bber
Pi nion Bearings
Type .... .. . . ... . .. . .. . . Adju stabl e Tapered Roller
Bea rin g Pre-Load Torqu e . . . . . . 565 - .904 Nm (5- 81b.in.) used bearings
without seal
1.3 56 - 1.695 Nm (12-151b.in.) new bearings
wi t hout seal
Side Bearings
Bearing Adju stmen t . . . . . . . . . Adjustabl e Tapered Roll er Shims
Lubricant Type and Capacity

Type .. . .. . . . .. . . . ... . . . E.P. SAE 90 Hypoid Gear Lubricant to
GMH Speci fication HN 1386.
For topping up purposes only, HN 1187 may
be used.
Capacity ... . . . .. . . . .... .... . 1.51itres (2 .5 imp. pi nts).
Differentia l Ring Gear to Case Bolts 75 - 81 Nm 55 - 60 lb. ft.

Differential Bearing Cap Bolts 54 - 61 Nm 40 - 451b.ft.
Differential Car ri er Cov er 34 - 41 Nm 25 - 30 lb. ft.
Differenti al Fill er Plug 34-41 Nm 25 - 30 lb. ft.
SPECIAL TOOLS
Tool No .
4A20 - 1 ........................ ............................................. ........... .. Driver
4A20-4 ............................................ ........ Remover - Rear Cup
4A20-5 ................................. .. ................. Remover - Front Cup
4A 2 1 -4 ..... ....... ............. .................... ..... ... Replacer - Rear C up
4A21 -5 ............ ........................................ Replacer - Front Cup
4A22 .................. .... Remover Rear pinion bearing cone ass
4A25 ... .... .......... .................. Differenti al sid e bearing in stall er
4A32 ......................... .. ..................... Pini on locating gauge set
AU139 ................................................. .......... ... .... .. Shim installer
Tools prefixed by '4A ' are ca rried over from previous
Holden rear axles . Too l No. AU 139 is available from
Kent - Moore Australi a Pty. Ltd .
NOTES
PROPELLER SHAFT AND UNIVERSAL JOINTS

INDEX
Subject Page Subj ec t Pag e
GENERAL DESCRIPTION oo o ooo oo o o o o o oo oo oooo o ooo o o oooo o ooo o oo o o o o o o o oo 04-21 CENTRE BEARING ASSEMBLY 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 00 00 00 0 04-24
SERVICE OPERATIONS o oo oo o o o o oo o o o o o o oo o oo o oo o o o oo o oo oooo oo oo oooo o o oo 04- 23 DISASSEMBLY oooooooooooooooooooooooooooooooooooooo o O ooOOO o OOO oOOO O O OO O 04-24
PROPELLOR SHAFT o oo oo o o oo o o o o o ooo o o o o o o oo oo oo o oooooooo o oo oo o o oooo o oo ooo 04-2 3 REASSEMBLY ooo ooooo o oooooooo oooooooooooooooooooo ooo oooooooooooooooo o oo 04-24
REMOVAL o OOO o o o o O ooo o oo oo oo o o o ooo o o o o o oo o o ooo oo o ooooo oo ooooo o ooo o o oo oo o oo o 04-23 UNIVERSAL JOINTS-SERVICING
INSTALLATION ooo oooo oo o o ooo oo ooo oo o o oo o oo oo o o oooooo o oooooo o oo o o o oo oo o oo 04-23 INFORMATION oooooo o o o oo ooooooooooo o o oo o ooooooooo oo o ooooooooooo ooooooooo ooooo oo 04-24
CONSTANT VELOCITY JOINT o o o o ooooo ooo o o oo oo o oo o o oo o o o o oo o o oo o o o 04-23 PROPELLER SHAFT ANGLES 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 04-24
DISASSEMBLY OOOO O O o o oo o ooo o oooo o o o o o o o ooo o o o oooo o oo o ooo O oo o ooooo o o oo o o 04-23 LUBRICATION SPECIFICATIONS o oo o o o OOOOOOOOOOOOOOOOOOOOOO O OOOO 04-24
REASSEMBLY OO OO O OOOO O OOOOOO OO o O oo o oo oo o O ooo o oo o oo oo o oo ooo o o o oo oooo o o o o 04-24 TORQUE WRENCH SPECIFICATIONS oo oo ooO oooo OO ooo OOOOOOOO 04-24
GENERAL DESCRIPTION
Figure 4-27
Propeller Shaft With Centre Bearing and CV Joint
The propeller shaft assembly used in VB models is a two

PROPEL L ER SHAFT
piece open design with needle bearing universal joints at
AX L E PART N o. CO L OUR
ENG IN E TRANS. the gear box and rear axle ends. Dri ve is transmitted be-
GV4
LD 1 tween the shafts thro ugh a co nstant velocity joint.
L 14 MC6 GU 4 Exc . G73 92003198 Gre y
L23 GV7 (Fig . 4-27) .
LD1 GV4
M20
L14 GU 4 Exc . G73 92003977 Black Front and rea r unive rsa l joints and the CV Join t are
M40
GU7 and GV7
L23 ultrasonically cleaned prior to assemb ly and they are
LD1 GV 4 sealed against th e in gress of foreign material du rin g th eir
L 14 MC6 GU 4 With G73 92003421 Gold
L23 GV7 normal service life, th erefore th e join ts must not be dis-
GV 4 mantled for periodic lubricati on.
LD1
7
L 14 M20 GV With G73 92003422 Violet The complete prope ller shaft is balan ced as an assembly
GU 4
L23
G70 and it is reco mm ended that if a front or rear shaft is re-
GV4 placed th e comp lete assembly should be balanced.
M20 Dark Blue
GU 4 Exc . G73 92000751
L36
M40 Fig. 4-28 gives propel ler shaft usage for th e various engin e
GU 7
transmission and rear axle opti ons on VB .
GV4
M20
GU4 With G73
L36
M40 A fully sealed ball bearing mounted in a reinforced rubb er
G70
92000750 Dark Green
cup supports the propeller shaft in th e centre locati on,
GV 4 (F ig . 4-30). Th e centre bearing rubb er cup is mounted on
L3 1 M21
GU 4 a carri er which is bolted to th e fl oo r pan (Fig. 4- 29).
GU4
L3 1 M4 1
G70
920007 49 Orange Thi s rubber mounting allows th e comp lete propell er shaft
limited tra ve l during rea r suspens ion movem ent.
Fi gure 4-28 The c hart (Fi g. 4-28) gives propeller shaft usage for the
Propeller Shaft Usage Chart - VB Model various engine / tran smission and rear axle op tions on VB .
FLOOR PAN
~-~~ ~rr= ~.
-dr~·-
A
. .lll-n·
~ riC \ en
~ EN G_I NE_C R ANI<~ ~ -
-- ..=r--u c
_/
.,m
en
z
en
6
UPPER CUP GUIDE ~z
& BO LT \ JJ
\ m
l>
C ENT RE BEAR I NG
JJ
R EI NFORCEM EN T . l>
><
r-
& BOLT
m
Lt en
~
NU T ~ r-- \ -yc.
"""'..,__
. - - Qo
""~
> BEND TABS TO L OCK --"'
-~
;-
N UT S
LOWER CU P GU I D E , CARR IE R VIEW IAI I

SECTION A-A BE N D TAB S OV ER A S SHO WN
&
Q .
'
:"'
VIEW~
16-20Nm
& 20 - 25 Nrn
Figure 4-29
Propeller Shaft Installation
SERVICE OPERATIONS
PROPELLER SHAFT INSTALLATION
Reverse to assembly operati ons taking care to observe th e
REMOVAL (Fig. 4-29) foll ow ing.
1. Remove centre bearing support to body rein forcement Care must be taken to use only genuine 'U' bolts and nuts
bolts. and new lock plates. Tighten th e nuts to 16-20 Nm .
2. Loosen and remove the two 'U' bolts that hold th e rea r Ensure that the centre bearin g support shims are in th e
universal joint flange and if necessary, tap th e end of co rrect location and tighten the bolts to 20-25 Nm .
the shaft lightely with a soft hammer to disengage th e
trunnions. The disengaged trunnions norma ll y have a
weld strap connec ting them together. If thi s is not
intact, suitable means should be em pl oyed to prevent CONSTANT VELOCITY JOINT
the trunni ons falling off the sp ider.
3. The propeller shaft can now be removed by pulling it
DISASSEMBLY
to the rear to disengage the universa l joint from yoke
from the transmission main shaft. 1. Remove propshaft assembly as previously outlin ed.
NOTE: 2. To ensure co rrect ali gnment of parts at reassembly,
use a straight edge and mark th e relative alignm ent of
(a) Take care to protect the outer diameter of th e front the CV joint and front and rear prop shafts.
yoke. Nicks or abrasions will damage th e tran s-
mission rear extension oil sea l durin g reassembly 3. (Fig . 4-30), remove the six ca p sc rews holding th e rear
and result in an oi l leak past the sea l. shaft assembly to the CV joint.
(b) Insert plug in the end of th e transm issio n rear 4. Using a hammer and soft punch, li gh tly tap th e rea r
extension to prevent loss of transmission oil. propshaft adaptor off the CV joint.
COAT SURFACE WITH SEALER HN1 58 1 DUST SHIELD

CENTRE BEARING
RUBBER MOUNT IN G
\ \ \
CIR C LIP
lJ-
-.....::::,
/ / USE THREAD SEAL ER
HN 1256 CLASS 1
1 RECESSED SOCKET HEAD SCREW TYPE 1A ON THE SE
SIX OFF SURFACES
& 40Nm.
Figure 4-30
Detailed View of Centre Bearing and CV Joint Assembly
5. Remove the CV joint to prop shaft rear retaining 4. Remove the centre bearing retaining circlip.
circ lips. 5. Using suitable press plates support the centre bearing
6. Usin g a hamm er and a soft punch remove the dust and rubber cup mounting assembly as close to the
cover forward s from the CV joi nt. propeller shaft as possible and press the centre
7. Slid e suitabl e press pl ates between the dust cover and bearing assembly off the propeller shaft.
CV joint to support the inner area of the CV joint as- NOTE: Take care not to damage the large diameter slinger
sembly. Press th e CV jo in t off the shaft assembly. which is fixed to the front propeller shaft tube .
8. Remove th e CV joint th rust washer and front circlip and
remove th e dust cover and boot. REASSEMBLY
1. Cleanliness of the bearing housing and associated
REASSEMB LY parts is of prime importance to ensure maximum life
Reverse to th e disassembly operations taking care to of the bearing.
observe the following: 2. Ensure that the centre bearing rubber cup housing and
1. Clean liness of the CV joint and associated pa rts is of front slinger are undamaged .
prime importance to ensure maximum life of the as- 3. Centre a new bearing in the rubber c up housing bore
semb ly. and using a suitable piece of tube on the outside track
2. In spect dust cove r and boot to ensure the re are no of the bearing, press the bearing into place until the
holes or damaged areas whi ch wil l all ow entry of dirt rubber retaining bead is visible.
or water. 4. Using a suitable length of tube against the inner race ,
3. En sure that joi nt is packed with 80 g lubricant to GMH press the bearing and rubber cup housing into place
spec ifi cati on HN 1583. After c lean in g th e surfaces on the propeller shaft.
apply a bead of sea lan t to GMH speci fication 5. Install the bearing retaining circlip.
HN 1581 aro un d th e con tact area of the companion 6. Install a new centre bearing rear slinger.
fl ange an d dust shi eld before final assembly of CV joint
assembly.
4. Ensure th at the scribed lines on the CV joint and front UNIVERSAL JOINTS - SERVICING
and rear shafts are aligned. INFORMATION
5. Coat th e spigot area of th e rear propshaft adaptor with
seal ant to GMH specifica tion HN 1256 Class 1, Type Replacement and servicing of the front and rear universal
1A, (Fi g. 4-30). joints is covered in the appropriate section of the HQ Shop
Manual Volume 3, Part Number M37017.
6. Coat th e threads of the six cap sc rews with sealant to
GMH specification HN 1256, Class 1, Type 1A. To rque
the screws to 40 Nm. PROPELLER SHAFT ANGLES
CENTRE BEARING ASSEMBLY The specified propeller shaft angles, for checking pur-
poses , are given in Fig. 4-31.
NOTE : Thi s bearing cannot be removed from the propshaft The angles are given in graph form so that the check can
with out ca using damage to the ball race and rear dust be carried out through the normal loaded range of the
sling er. New parts must be installed when the prope ller suspension.
shaft is bein g reassembled.
Three separate sets of angles are shown in the graphs. The
DISASSEMBLY left grap h is for L6 with standard axle, the centre one is for
V8 with standard axle and the right hand graph is for V8
1. Remove th e CV joint assembly (see prev ious secti on).
wit h heavy duty axle.
2. Be nd th e tabs to ex pan d th e upper and lower centre
beari ng cup gui des and remove them from th e centre
bearing rub be r cup . (Fig. 4-29).
LUBRICATION SPECIFICATIONS
3. With the use of a hamme r and sui tab le punch , remove Front & Rear Universal Joints .... Lithium Grease to GMH
the centre beari ng rear slinge r. Specification HN 114 7
NOTE: This part must be discarded once it is removed and Constant Velocity Joint ..... Molydenum Disulphide
a new part installed. Grease HN 1583

Nm
Nuts - Rear Universal Joint 'U' Bolts 16-20Nm
Bolts- Propeller Shaft Centre Bearing Cup
Guide to Carrier 20- 25Nm
Bolts- Propeller Shaft Centre Bearing
Cup Guide to C:mier ..... 20-25Nm
Bo lts- Propeller Shaft Cen tre Bearing Carrier
to Centre Bearing Reinforcement ...... 20-25Nm
Sc rew - Recessed Socket Head Constant
Velocity Joint .. ................. 40Nm
AXLE POSI T ION (mm )
A XLE TYPE :- BASE V EH ICLE FULLY - OPT IONED V EH I CLE
ENG I NE TRANSMISSION
SA LISBURY
KERB 1 PASSENGER 5 PASSENGERS GVW KERB 1 PASS ENGER 5 PASSEN G ERS GV W
L6 SMALL MC 6 ,M20 ,M40 360.7 350 ,3 302 ,6 285 ,1 350, 8 341 ,7 295 ,4 278 ,9
V8 SM A LL M 20 , M 40
360 ,1 34 9,7 302 ,2 28 4 ,7 347 ,3 338, 6 292,8 I 27 6 .6
V8 LAR G E M2 1, M4 1 --
:c
m
UNDERSIDE OF REAR FEND ER OPEN I NG - - - r - - - - - '
)>
:c
en
c
ANG LE 'B'
en
"'C
m
z
en
0
~z
:c
I·
m
AX L E JO I NT ANG L ES AXLE JO I NT A NG L ES
AXLE
JO INT A N G LES )>
•••
POSI TI ON
POS ITI ON
1-t--· .., .;· . . . . ·--· _,_ l"' :::: :::...:-
POSIT I ON
:c
., .. 360 r 7
---- ~
360 ---rjt~~~~;r.~~~~~ )>
360
350 -~~@§~~~~~~~~~~~
~ ~!--'·
350
....,...+l·h·
..y .
141
350 r=:=:: ::-;:: :::j:: ~ : .::-
.f ..
'-'- ><
r
340
-~
rl llllt1:x: 340
f:::::'•
F:: :11'
:II :
·jj·
:r:
1
"" ~· · ;· ~:.:.:.:.· --·-
; ? ~: - ~~:: 1:; ::::
340 --~jt~~~~;f~~~~~ m
en
330 ----~~~ti~~~~~~~~~] 330
A N G LE ;A ,
~ :~=- ~- =
11:[ :L:: lSJi f±_A NGLE ' C'
,., ••-' .:::± ,,_ ---=~;. ~---'--.~~
'--'-= = 330 ---g=.t4t±=+~#~3~ Qo
320 ---f.~~~~~~tt=tiJR~ 320 ~~~~~~~~~/r~~~~
•C•
::
320 ::::j.:: :::: ::: j :;;:.e::::.:.r,..- AN G LE ' B'
"'C
~;[_ ;~c~. j-\\hi~

:c
31 0 ----~~~~~~~~~~~~~~ 31o -~~~H~~~~~~~~~ 0
"'C
3111111 m
300 300
290 290
r
AN'(;U.~--±::=::::.!.Jl-'-f.;........J +<-.. -+-- 4 r
28 0 ·==FTI 280 -.;..:;.;; . . .. f-.-h· .:,\ t-1.:..;.:..::
28 0 m
=tE#r=F::J::;:;d II 1 Ii, I
- :_........j,
--::.:. --~-H-'
==='2 ·-
: :-r:-:: t: i ·:;r
:c
- 4 0 - 30 - 20 - 10 oo 10 20
!
30 40 50 - 30 - 20 - 10 oo 10 20 30 40 50 60 - 30 - 20 - 10 oo 10 20 30 40 50 60 en
::I:
)>
L 6 - SMAL L SA LISBUR Y 178mm R I NG GE A R V 8 - SMALL SALISBURY 178mm R I NG GEAR V8 - L A R G E SALISBURY 190mm RING G EAR
~
0
~
I
Figure 4-31 1\)
Propeller Shaft Angles U1
NOTES
BRAKES 05-01
SECTION 05
BRAKES
Subject Pagt; Subject Page
GENERAL DESCRIPTION ............................................... 05-02 BRAKE DISC ..................................................................... 05-23
MASTER CYLINDER ........................................................ 05-05 REMOVAL .................................................................. 05-23
PROPORTIONING VALVE ...................................... 05-05 REPLACEMENT ......................................................... 05-23
OPERATION ............................................................... 05-05 DISC BRAKE REFINISHING .................................... 05-23
DISASSEMBLY OF MASTER CYLINDER ............. 05-05 DRUM BRAKE (8VK & 8VL) .......................................... 05-27
INSPECTION AND REPAIR .................................... 05-06 MANUAL ADJUSTMENT ......................................... 05-27
REASSEMBLY - MASTER CYLINDER MAIN BRAKE SHOES ......................................................... 05-27
BORE ........................................................................... 05-06 Removal .............................................................. 05-27
REASSEMBLY MASTER CYLINDER To Replace Brake linings ............................... 05-27
PROPORTIONING VALVE & DIFFERENTIAL Inspection ........................................................... 05-27
WARNING SWITCH SECTION ................................ 05-07 Replace ................................................................ 05-27
ASSEMBLY - RESERVOIR ..................................... 05-08 WHEEL CYLINDER ............................................................05-27
BLEEDING .................................................................. 05-08 REMOVAL .................................................................. 05-27
MASTER-VAC SINGLE BOOSTER ............................... 05-09 DISASSEMBLY .......................................................... 05-27
OPERATION ............................................................... 05-09 INSPECTION .............................................................. 05-27
Released Position ............................................. 05-09 ASSEMBLY ................................................................. 05-27
Applying Position .............................................. 05-09 INSTALLATION .......................................................... 05-27
Holding Position ................................................ 05-09 BRAKE DRUM ................................................................... 05-30
No Vacuum Condition ..................................... 05-09 INSPECTION .............................................................. 05-30
DISASSEMBLY .......................................................... 05-09 Cracked Drum .................................................... 05-30
CLEANING AND INSPECTION ............................... 05-12 Scored Drum ...................................................... 05-30
PREPARATION FOR REASSEMB LY .................... 05-12 Grooved Drum ................................................... 05-30
ASSEMBLY ................................................................. 05-13 Out of Round Drum ......................................... 05-30
MASTER CYLINDER ASSEMBLY TO RECONDITIONING .................................................... 05-30
MASTER-VAC ............................................................ 05-13 Surface Finish .................................................... 05-30
MASTER-VAC TANDEM BOOSTER ............................. 05-15 BRAKE DRUM BALANCE ....................................... 05-30
OPERATION ............................................................... 05-15 PARK DRUM BRAKE (8VX & JM8) ............................. 05-31
Released Posit!on ............................................. 05-15 ADJUSTMENT ............................................................ 05-31
Applied Position ................................................ 05-15 BRAKE SHOES ................................................................. 05-31
Holding Position ................................................ 05-15 REMOVAL .................................................................. 05-31
No Power Condition ......................................... 05-15 INSPECTION .............................................................. 05-31
DISASSEMBLY .......................................................... 05-15 REPLACE ................................................................... 05-31
CLEANING AND INSPECTION ............................... 05-15 PARK BRAKE HANDLE .................................................. 05-31
ASSEMB LY ................................................................. 05-17 REMOVAL .................................................................. 05-31
REPLACEMENT ......................................................... 05-31
MASTER CYLINDER ASSEMBLY TO
PARK BRAKE CABLE .................................................... 05-31
MASTER-VAC ............................................................ 05-20
REMOVAL .................................................................. 05-31
DISC CALIPER (FRONT & REAR) ................................ 05-21
8VK and 8VL Models ....................................... 05-31
DESCRIPTION ............................................................ 05-21
8VX and option JM8 Models .......................... 05-31
PAD REPLACEMENT (FRONT AND REAR) ....... 05-21
REPLACE ................................................................... 05-31
Removal .............................................................. 05-21
BRAKE PEDAL ................................................................. 05-31
Installation .......................................................... 05-21
REMOVAL .................................................................. 05-31
CALIPER OVERHAUL (FRONT AND REAR) ...... 05-21
REPLACE ................................................................... 05-31
Removal .............................................................. 05-21
DIAGNOSIS CHECK SHEET .......................................... 05-37
Disassembly ....................................................... 05-21
SPECIFICATIONS ............................................................. 05-38
Cleaning .............................................................. 05-21
TORQUE WRENCH SPECIFICATIONS ........................ 05-39
Assembly ............................................................ 05-21
Replace ................................................................ 05-21
05-02 BRAKES
GENERAL DESCRIPTION
All 'VB ' mod els are fitt ed with a tand em master cylinder elimin ates all tend ency to lock at maxi mum braking
whi ch all ows adequate braking to stop th e vehicle should pressures. The rear shoe gives an equal braking effort for
a failure occ ur in either system. reverse braking and both shoes hold equally aga in st for-
The master cylinder body in corporates a co mbin ed pro- ward and reverse movement with th e park brake applied .
porti onin g valve and pressure differential switc h. In th e Beca use the shoes are abl e to floa t on th e anchor, th ey
event of a failure to th e front brake system th e pro- more readi ly co nform to th e shape of the d rum . As th e
porti oning valve is by- passed all owing full rea r brake ap- brake adjuster sc rew also acts as th e park brake strut , both
pli ca ti on. park and se rvi ce brakes are ad justed simu ltan eously
during no rm al brak e ap pli ca ti on).
Single di aphragm vacuum boosters are used on six
cylind er models without rea r wh ee l di sc brakes, except Rea r brakes on 8VX models or optionally equipped
wh en eq uipped with both automati c transmi ss ion and air vehi cles are solid d iscs with sliding ca lipers. Th e park
conditioning together. All oth er models are equipped with brakes are manual ly adj usted, duo servo type and are
tandem diaphragm boosters. attached to a pressed metal plates bol ted to th e axle
housin g. Thi s pl ate also supports th e calipe r. Th e spec ially
Fron t brakes on a! l model s are ventilated d iscs with lig ht
mac hined inn er surface of th e disc hub acts as th e brake
weight sli ding ca li pers. Standard rea r brakes on 8VK and
drum .
8VL models are self adj usting , leading / trailing, (floating
shoe d rum brakes. Lead ing/ trailing shoe brakes use only Th e park brake is operated by an eq ualizer ca bl e attac hed
one shoe, in forward rotation , with a low wedg e action that to th e fl oo r mounted, button release, pa rk brake lever.
BRAKES 05-03
RELAXED POSITION
POPPET PISTON FROM MAS T ER CYLINDER

BREATHER
AND WAVE WASHER
SEAL BLOCK
Figure A
ABOVE CRACK POINT
PRESSURE SPRING
POPP ET PISTON FROM MASTER CYLINDER
Figure B
05-04 BRAKES
RELEASED POSITION
PRESSURE
SPR I NG
POPPET PISTON TO MAS T ER CY LIN DER
Figure C
FRONT SYSTEM FAILURE
WA RNIN G L A MP SWIT CH
FROM MASTER CYLINDER WARN IN G LA M P SPOOL

POPPET PISTON ACTUAT IN G SW ITCH
FigureD
BRAKES 05-05
MASTER CYLINDER
IMPORTANT : THE OPERAT IN G PRESS UR ES
OF THE PROPORTION ING VALVE ARE STAMP ED
PROPORTIONING VALVE ON THE REAR END OF THE CY LINDER AND IT
IS MOST IMPORTANT THAT WHEN REP LA CIN G
OPERATION AN IDENTICAL CY LINDER 1's USED . '
In th e relaxed posi ti on (Fig. A), the poppet piston is held

back in th e seal bl oc k by th e larg e press ure spring acting
on a waved washer attached to th e smaller end of the
piston. Th e poppet va lve is held against the end of its
retain er by a light return spring and brake fluid is free to
pass from th e master cylinder, through a bore in th e poppet
pi ston to th e rear brakes.
Wh en master cylinder press ure is in c reased to th e pro-
port ioning valve c ra ck point (Fig . B), brake fluid pressure
acts on th e difference between th e two areas of th e poppet
pi ston forcing it to move forward in th e sea l block against
th e large press ure spring . The co ni ca l seat in th e pi ston
preventing an inc rease to th e rear brakes unti l maste r
cylinder pressure is furth er in creased .
As master cylinder press ure is in c reased , fluid press ure on
th e small er end of th e pi ston builds up and ove rcomes th e Figure 5·1
lower press ure now on th e larg er end, forc ing the piston
back off th e poppet va lve. Part of this flu id press ure now
can pass th ro ugh th e pi ston to act on the larger end and
again force th e pi ston forward to seal on the poppet va lve .
Thus as th e master cylinder press ure increases above
proport ion ing va lve c rack point, th e pi ston oci ll ates against
th e poppet valve proporti oning the rear brake fl ui d pres-
sure to a predeterm in ed lower valve to that of th e front
brakes.
Wh en th e brake peda l is re leased (Fig . C) , and fluid
pressure from th e master cylinder drops, th e pressure of
th e rea r brake fluid unseats th e poppet valve allowing fluid
to return to th e master cylinder and th e pressure spring to
retu rn th e poppet pi ston to its relaxed pos ition .
Should the front brake system fail (Fi g. D) , th e warning
lamp actuatin g spool will move forward taking th e poppet
valve with it. Thi s will allow full press ure to th e rear brake
system , as whil e th e pop pet pi ston is forced forward , it ca n
no longe r seal on th e poppet valve.
NOTE:
1. Because of the spec ial rubb er co mpound s used , thi s
master cylinder MU ST BE REPAIRED USING ONLY
THE GE NUINE GMP &A OR PBR ' MAJ OR ' KIT . Thi s kit
inc lu des new rubber components. Ensure all sec ti ons
of th e cylind er are re paired. Figure 5-2
2. Th e operating press ures of th e proporti oning valve are
stamped on th e rea r end of th e cylinder and it is most
important that , should a cylin der need replacing , an
id entical cy lind er be used. Refer to (Fi g. 5- 1) for 3. Separat e by hand , the plasti c rese rvoir from aluminium
stamp in g locati on. body. Remove th e rese rvo ir sea lin g grommets.
3. Wh en remov in g th e master cylinde r from the booster, 4. Remove pressed steel end cap fitt ed to th e openin g of
care must be taken not to disturb the pushrod an d not th e main bore by prising up the two locating lugs.
to depress the brake peda l aft er the cylinder is re-
CAUTION: Hold cap firmly with one hand during this op -
moved.
eration to ensure that the primary piston does not spring
out of th e bore once th e cap is free.
5. Remove primary pi ston and return spri ng.
DISASSEMBLY OF MASTER CYLINDER (Fig. 5-2) 6. Fu lly depress and hold secondary pi ston down th e
bore , remove rese rvoi r attaching bolt from th e cylind er
1. Clean th e outsid e of th e master cylinder and remove body, th en remove secondary pi ston .
res ervoir cap . Pour out and discard any brake fluid tha t 7. Unscrew the plastic brake warning switch from side of
remain s in cylind er. master cylind er body.
2. Un sc rew and remove hexago n nut and wa sher located 8. Unscrew and remove hexagon plug located at the
inside plasti c rese rv oir . flange end of cylind er.
05-06 BRAKES
RESERVOIR
COPPER GASKET
SECONDARY PI ST ON CU P RETAII\IER
*SECO N DARY SEAL

' PR IMARY SEALS - - - ' - - - - - - - - - - - - - - - - l
' I MPOR T A NT : T H ESE SEA LS M UST BE A SSE MBLE D IN TH E D I REC TI ON AND POS ITI ON SHOWN .
Figure 5-3
CAUTION: Hold firmly with one hand during this op era tion 3. Inspect th e master cylinde r bo res for sign s of etchin g,
to ensure in ternal parts do not spring out. pittin g, scorin g or rust , and if in poo r co ndition rep lace
9. Remove al umin ium sea l bl oc k and pi ston assembly. If th e cy linder. TH IS CY LIND ER IS NOT TO BE HO NED.
assembly is stuc k in th e bore afte r remov in g hexago n 4. Wh en replacing c ups, plasti c re taine rs may be re-
plug , tap flange end of cylind er on so ft wooden bench moved by c utti ng wi th a sha rp kn ife or raz or blad e,
to assist removal. ens urin g that pi ston is not damaged in any way .
1 0. Remove large spring and pressed steel popp et re-
tain er; these items sho ul d fa ll out during sea l block and
pi ston assembly removal , if not, remove wit h long nose REASSEMBLY - MASTER CYLINDER MAIN BORE
pliers.
11 . With draw pl astic poppet piston and spoo l asse mbl y
USE ONLY MAJOR REPAIR KITS AND IN STALL ALL
usin g long nose pli ers gri pping th e outside of th e
PARTS SUPPLI ED.
plasti c poppet pi ston . If the po ppet piston se parates
from the spoo l assembly then remove spoo l usin g th e NOTE: Proporti on in g va lve seal block and pi ston assembly
long nose pli ers grippi ng the poppet reta in ing ex- sealed in plasti c bag has been pre-lu bri ca ted.
tension on end of spool. DO NOT WAS H - ASSE MBLE AS SUPP LI ED.
Eac h kit contains three prima ry seals, a seco ndary sea l and
INSPECTION AND REPAIR two sea l retai ners for assemb ly on to the master cylind er
1. Wash all part s in c lea n methyl ated spirits and inspect pistons. It is extremely important that these seals be placed
the parts for chipp ing, excess ive wear or damage. in their correct positions. Prima ry sea ls may be id entifi ed
2. Check al! recesses, openin gs and intern al passages to by th e presence of six rec upe rating grooves around th e
be sure th ey are open and free from foreign matter. Use ci rc umfe rence of the sea l (Fig. 5-3 )
an ai r hose to bl ow out d irt and c lea nin g so lut ion. Place 1. Before assemb ly, lu bri ca te int ernal parts and master
all part s on a c lean pan or pape r. cylind er bore wi th clea n, recomm end ed brake fluid .
BRAKES 05-07
2. Install '0 ' rin g sea l in to the sma ll er of the two grooves
at the end of th e seco ndary pi ston. Into th e seco nd
groove, instal l one of the three id entical c up sea ls
ensurin g th at th e sea l lip fa ces away from th e '0 ' rin g
seal.
3. Fi t one of the three identical cup seals into th e shall ow
sea l groove at th e return spring hol e end of the sec-
ond ary pi ston, ensuring that th e sea l lip fa ces away
from th e '0' rin g fitt ed in step No. 2. Locate pa rt of th e
plasti c cup sea l re tainer in groove on piston and hold
in posit ion with thumb (F ig . 5-4). Using a smal l poin ted
tool, clip the re tainer in to th e remaining part of th e
groove ens urin g that co mpl ete locati on is achieved
(Fig. 5-5). Care sho ul d be taken to avoid damage to
piston or c up sea l. RE TAINE R
NOTE: Retainers should be disca rd ed if pistons do not

have loca tin g groove as shown in Fig. 5-6. Figure 5-5
4. Install onto th e primary pi ston one of th e three identica l

cup sea ls, located in th e sha ll ow sea l groove oppos ite
to th e push rod hole end of th e pi ston, ensuring that
the sea l lip faces away from the push rod hole end . Fit
rema inin g plastic retaine r to primary piston as in Step
3.
5. In stall th e seco ndary sea l into th e groove at th e pu sh
rod hole end of th e primary piston, ensuring sea l li p
fa ces away from th e push rod hole end of piston .
6. Fit seconda ry return spring into end of seco nda ry
pis ton. Sp rin g end first, ca refu lly in sta ll piston as-
se mbl y into main bo re. Fully stroke secon dary pi ston
and whil e held at th e bottom of th e bore install res-
ervoir attach in g bo lt and new co pper gasket. Screw
bolt the full length of thread by hand before tightening
to 6.2-6.8 Nm.
7. Fit primary return sprin g on to th e pi ston opposite pu sh
rod, hold end, and sp rin g end first, carefully in sta ll
piston assem bly into th e main bore. PRIMARY PISTON SECO NDARY PISTON
8. Dep ress primary pi ston unW pu sh rod hole end is flu sh
with front end of main bore , then install retaine r plate
Figure 5-6
over end of main bore and retain in position by bendi ng
th e two fi xing lugs into th e machin ed groove on the
master cy lind er body locatin g sp igot.
1. Before asse mb ly, lubri ca te bore and in tern al part s with
clean, reco mm end ed brake fluid .
2. Pos ition the proportionin g va lve bore vertically , then
carefu ll y lower the spool assembly, electrical sp rin g
end first, into the bore ensuring tha t the electri cal
spring remain s assembled on th e spool.
NOTE: Should electri cal spring become separated from
spoo l, replace with turned-down coil on spool.
3. Assemble th e pressed steel poppet retain er, large end
first, into th e bo re and ove r the plastic poppet.
4. Push, with th e finge r on the poppet retai ner, until th e
spool assembly is located in th e co rrec t position down
th e bore. Chec k th e dim ension from th e top of th e bo re
to th e small end of the poppet retainer. Th e dimension
Figure 5-4
should be app rox im ately 44 .5 mm wh en position ed
co rre ctl y.
REASSEMBLY MASTER CYLINDER 5. Locate large spring ove r popp et retain er.
PROPORTIONING VALVE AND DIFFERENTIAL 6. Ca refully in stall sea l block assembly - washer end first,
WARNING SWITCH SECTION into th e bore onto the large sprin g.
7. Sc rew plug into end of bore.
NOTE: Wh en using a repair kit in stall all new parts. Sea l
block and piston assemb ly sea led in plasti c bag has been CAUTION: Screw by hand until th e head of plug is 1.6 mm
pre- lu brica ted . DO NOT WAS H - ASSE MBLE AS SUP- under th e cylinder mounting flange, th en tighten plug to
PLIED . 34-40 Nm.
05-08 BRAKES
~
QU~
~ffq)
EL ECT RI CAL SPR I NG (SEC U R EL Y A SSEMBLE D
WI TH T U R NED DOWN COIL ON SPOO L).
~ SPOOL A SSE MBL Y (S UPPLI ED FUL LY ASS EMB L ED)

\ BREATHER FILT ER - T O ALLOW M O V EM ENT OF PISTO N W IT H THE 'S EAL BLOCK '.
SEAL BLO CK ASSEMBLY
(S UPPLIED I N KIT FU L LY A SSE M BLED A N D PRE - LUB R I CAT ED)
DO NOT WASH - I NSTALL AS SU PPLIED
Figure 5-7
ASSEMBLY - RESERVOIR BLEEDING

1. Fit rese rvo ir join ing gromm ets into cylin der body Fill th e master cylind er with reco mm ended brake flu id and
locati ons. bl eed on th e bench pri or to repl acing on the vehi cle. Check
2. Assembly '0 ' ring onto rese rvo ir attac hin g bolt. comp ensatin g port clea rance by watching for a spurt of
3. Assembly reservo ir over attac hin g bol t and into th e flu id in th e front secondary side rese rvoir wh en th e pi stons
joining grommets. are sli ghtly depressed . After bleeding, bl oc k master
cy linder outl et ports to prevent flu id escap ing.
4. Fit reservoir attac hing washer and nut on to th e at-
taching bolt located in sid e th e second ary sect ion of Rep lace master cy linder ensuring hyd rauli c pipes are
th e rese rvoir and tig hten to 5-5.6 Nm. sec urely co nn ected . Top up fl ui d - GM 4653 M, Type 450
5. In stall rese rvoir cap into rubb er rese rvoir sea l ensurin g - to 6 mm below rim of reservoir.
that the 'front ' markings are in the sam e di rec tion .
6. Fi t cap assembly to reservoir with 'front' ma rk to front
of vehicle ensuring that the outsi de lip of th e rubbe r
cap clicks over th e reservoir location bead.
BRAKES 05-09
MASTER-VAC SINGLE BOOSTER Holding Position (Fig. 5-10)

During application of the brakes, the 'reaction' aga in st the
OPERATION air valve plunger is working against the drive r to close th e
atmospheric port. With both atmospheric and vac uum
Released Position (Fig. 5-8 ) ports closed, the Master-Vac is in th e holding positi on.
With the eng in e running and th e brake peda l released, When both valves are closed, any degree of brakin g ap-
vacuum c reat ed by th e engine removes air from the plication attained will be held until either th e atmosp heri c
Master-Vac cons tant vacuum c hamber through the vac uum port 'A' is reopened, by depressing th e brake peda l fu rth er,
chec k valve mounted in th e fron t shell and co nnec ting hose to increase the brake application , or by decreas ing th e
to th e engin e intake manifold . peda l appl y force to reo pen th e vacuum port 'V' and de-
With th e brake pedal assembly in the released pos iti on, th e c rease th e brake application.
valve operating rod and valve plunger are held to the rea r Wh eneve r th e app ly fo rce on th e brake pedal is held
by th e va lve return sp ring , th ereby closing th e atm os ph eri c co nsta nt for a moment the valve returns to its holding
port and open in g the vacuum port 'V'. This co nn ects th e pos ition.
con trol vac uum chamber to the co nstant vac uu m c hamber. Howeve r, upon reac hing the fu lly appli ed positi on, th e air
Thus vac uum is present on both sides of th e d iap hragm , valve plu ng er moves away from the floatin g poppet (con-
and the diaphragm return sp ri ng holds th e d iaph rag m trol) valve to open th e atm osph eric port and ad mit max-
pressure plate and valve body , valve rod and plun ge r as- imum air pressure to the c hambe r at the rea r of th e
semb ly and th e hydraulic push rod in the full y released diaph ragm (as shown in Fi g. 5-9) . Hen ce wi th fu II vacuum
posi ti on. in th e constant vacuu m chamber (at the front of the dia-
With the hydrauli c push rod in the released posi tion, th e phrag m) th e max im um bra ke ass istan ce or 'boost' is ob-
co mp ensatin g ports in the master cylinde r are open to tain ed.
permit brake fluid to eith er return from the brake system to
th e fluid rese rvoi rs or enter the brake system from the flui d No Vacuum Condition
rese rvoi rs to co mp ensate for expans ion o r loss of flui d from In case of vac uum so urce in terrupti on , as th e brake pedal
th e brake system. is pushed down , th e va lve rod and plunger assembly
co ntacts th e reacti on d isc whi ch moves the hydraulic push
rod and operates th e master cyli nder.
Applying Position (Fig. 5-9)
Th e pedal ap ply force req ui red for man ual app lica ti on such
As the brake pedal is depressed the valve rod moves as desc ribed, is co nsiderably greater than with vacuum
ass istance .
forward co mpressi ng th e valve rod re tu rn sp ring whi c h
forces th e floating poppet valve against the vac uu m po rt
seat 'V' in th e va lve body. This action disco nnects th e
con trol vac uum chamb er from th e co nstan t vac uu m
chamber in which th ere is still full vacuum.
DISASSEMBLY (Fig. 5-11 )
Any addi tional move ment of th e valve rod in the app lied
direction pu shes the valve plunger forwa rd away fro m its Du e to th e design of th e Master-Vac , a specia l tool 5A8
seat 'A' on th e fl oating poppet (co ntro l) va lve ad mittin g mu st be used fo r d ismantl ing and assembly. The foll owing
atmospheric pressu re through th e air c leaner element and proced ure is based upon the use of th is too l (F ig. 5- 12) .
silence r into th e co ntrol vacuum c hamber.
Wi th th e front side of the diaphragm exposed to vac uum 1. Remove master cy linder from front she ll (if not pre-
and atmos ph eri c press ure on the rea r side, a force is viously re moved) .
developed which overco mes th e diaph ragm return sprin g 2. Li ft out hyd rauli c pu sh rod and sea l assembly from the
force and moves th e diaph ragm press ure plate, va lve body fro nt shell.
and hydrauli c push rod (v ia the rubbe r reac ti on d isc) 3. Sc ri be a lin e across th e front and read she ll s to fac-
forwa rd to actuate th e hydraulic bra ke maste r cylin der. ilitate posi ti on ing on reassembly.
Entry of air press ure to th e co ntrol vac uum chamber 4. Sec ure base plate of separatin g tool in a vice and
co ntinu es until the hydraulic pressure developed within the engage th e studs of the rear shell in the base plate.
master cy lind er crea tes a co unter force (to the rear) acting Engage the two front shell studs in the too l lever as -
through th e hydraulic push rod and reacti on disc aga in st semb ly and sec ure with two master cylinder lock nuts .
the valve rod and plun ger. The rubber reaction di sc d is-
5. With th e hold-down c lamp in co ntac t with the as-
tributes thi s force between the valve body and the va lve
sembly to preve nt the front cove r from ejecti ng , rotate
plun ger in proportion to their respective co ntact areas.
the lever anti-c lockwise so that c ut outs in front shell ,
(Th e proporti on of reactive force applied to the valve
line up with the indentati ons of rear shell.
plung er is co ntroll ed by design to ens ure maximum powe r
co nsistent with maintaining pedal 'feel'). The resu lta nt 6. Back off on hold down clamp suffi c ien tl y to remove
force actin g aga in st the valve rod and plung er moves th e front shell and return spring .
plun ge r slightly to th e rear in relation to the valve body. Th is 7. Remove the rear shell from th e tool base plate and
movement closes off th e atmo sph eri c port 'A' to co ntro l remove dust co ver and sil ence r from va lve body and
entry of ai r (at atmospheric pressure) into the co ntrol valve rod .
vac uum c hambe r. 8. If check valve re quires repl acement, push it and th e
Sin ce thi s co unter force or reaction fo rce is in direct rub ber gromm et out of the fro nt shell .
propo rti on to th e hydraulic press ure developed within the 9. Re move va lve body assemb ly from rear shell.
brake system, th e driver is able to mai tain 'fee l' of the 10. Remove diaphrag m by stretc hing it out of th e locatin g
degree of brake application attained. groove in va lve body.
05-10 BRAKES
VACUUM PORT V (CLOSED)
ATMOSPHERIC PORT A
(CLOSED )
Released Position
Figure 5-8
ATMOSPHER I C PORT A
(OPEN)
Applying Position
Figure 5-9
BRAKES 05-11
VACUUM PORT V (CLO SE D)
ATMOSPHERI C PO~T A
(CLOSED)
Holding Position
Figure 5-10
4 5
il()J
1 SE AL _ FRONT SHELL
. PLATE - FRO NT SE AL SU PPOR T
~: HYDRAULI C PU SH ROD,_ 11. DIAPHRAGM PRESSURE PLATE
4. VACUUM CHECK VAL Ue 12 DIAPHRAGM
5. GROMMET 13. VALVE ROD AND PLUN GER ASSY
6 FRONT SHELL 14: SE AL _ REAR SHELL
7.. DIAPHRA GM RETURN SPRIN G 15 REAR SH E LL
8 REACTION DI SC 16: AIR CLEARNER ELEMENT
9.. VALVE PLUNGER LOCKI N G KEY 17. Sl LEN CER Disassembly
10. VALUE BODY 18. DUST COVER
Figure 5-11
05-12 BRAKES
NOTE: Smear al l rubb er parts with brake fluid or rubb er

grease to GM Specification HN 114 7 lubri can t pri or to
TOOL No. 5AB
in stal lation. If unit is to be stored for any leng th of tim e aft er
/ overhaul, rubber grease sho uld be applied liberally to

rubb er parts and sides of push rod, both on shaft and
rea cti on face .
CAUTION: This grease must not be used on th e rubb er

diaphragm . The end of the hydraulic push rod protruding
out of the front seal must be free from this grease, as it is
detrimental to the master cylinder seals.
ASSEMB LY
1. If rear vacuum seal was removed support rear shell on
wooden block with studs facing downwards . Pl ace new
seal in cavity and drive in seal using a sui tabl e piece
of tubing .
2. Inse rt valve rod and plunger assembly in valve body
then press down to install va lve plunger locking key
(Fig. 5-13).
3. Push reaction disc into valve body ensuring th at it is
installed with pimple to rear.
Figure 5-12
4. Ca refully install pressure plate on to back of valve
Separating Master-Vac Unit
body. Lubricate inner sealing edge of th e diaphragm
with Rubber Grease and then assembly it into the valve
body groove to secure pressure plate in positi on .
11. Carefully rem ove steel pressure plate from valve body
ensuring that the thin back edge of th e diaphragm 5. Insert valve body hub through sea l in th e rear shell , and
groove is not damaged d uring thi s operation . lubricate outer edge of diaphragm with Rubber Grease
to fa c ilitate easier assembly of th e shell s.
12. Hold the valve body horizontally with th e valve plunger
locking key reces s lowermost, depress va lve rod and 6. In stall rear shell on base plate of spec ial too l 5A8 and
plunger assembly slightly to all ow th e loc king key to sec ure in posi ti on.
fall out. 7. Install return spring in rear shell .
13. Withdraw valve rod , plunger, air filt er and silencer 8. Positi on front shell on rear shell with sc rib e marks
assembly from the va lve body. adjacent to one another, secure bar to fron t she ll stud s
14. Push out rea cti on disc with a blunt tool. with th e two attaching nuts.
15. Inspect rear vac uum sea l, remove onl y if necessa ry
and if a new sea l is avai lab le.
16. To remove sea l, support rear shell on woo den bl oc k CONTROL VALVE
ASSEMBLY
and drive out sea l with a pun ch. OPERATING ROD
CLEANING AND INSPECTION

1. Wash all parts thoroughly in meth ylated spirits.
2. Blow out all passages , orifices and valve holes. Air dry
and place cleaned parts on c lean paper or lint free
clean cloth .
3. If slight rust is found inside eith er th e front or rea r
shells, polish clean with croc us c loth or fin e emery
paper, wash clean with meth ylated spirits.
4. Inspect all rubber parts for cu ts, ni cks or oth er dam -
age. Replace where necessary.
NOTE: Th e valve rod and plunger are only se rvi ced as a
compl ete assembly, repla cing of the individual pa rts must
not be attemp ted.
5. Th e air filter and silencer should be blown ou t with
compressed air to remove any dust or dirt particles. If
th ey are badly co ntaminated it is permissible to wash
in soapy water and bl ow dry with compressed ai r.
PREPARATION FOR REASSEMBLY VALVE PLUNGER

STO P KEY
Make sure all rubb er parts are clean. Rewash in methylated
spirits if there is any doubt of c leanl iness. Ens ure grease
or mineral oi l do es not co ntact rubb er pa rts of Master-Vac Figure 5-13
unit. Removing Retainer lock Key
BRAKES 05-13
9. Tighten hold down c lamp and co mpress th e dia- In sta ll master cylind er to master-vac unit, sprin g was hers
phragm re turn spring until the front shell is mated with and nuts and tighten to 13.5 Nm torqu e.
th e rea r shell. After assembly of the master cylinder to master-vac, th e
10. Rotate bar c loc kwise until front and rear shell s are primary c ups of th e master cylind er must be c lea r of th e
loc ked togeth er, th en remove from too l. co mpensating holes when the unit is in th e released
11 . Install air filt er element into va lve body. posit ion, thi s van be chec ked by partially filling the res -
12. Pl ace sil ence r and dust cover ove r va lve rod and valve ervoir and th en stroking th e master-vac .
body. If air bubbles appear or the fluid spurts from th e com-
13. In stall hydrauli c push rod into fro nt shell and ensure pensating port s, then th ey are clear. If the primary cups
th at end of push rod is located co rrectly in valve body . ove rlap the comp ensating ports th ere will be no fl ow of air
or fluid through the co mpensat in g ports wh en the uni t is
14 . Positi on support plate into front seal, and install th em
stroked .
in to front shell recess.
15. Check th at hydrauli c push rod protrudes specified NOTE: If thi s condition exists do not use.
distance from face of front shell (Fig. 5-21) . Fai lure to c lear the compensatin g ports in the released
16. In se rt grommet and th e fit vac uum c heck valve into th e position ; traps fluid in front of th e primary cups and hold s
front shell. pressure in the hydraulic lin es ca using wheel drag . If th e
compensating ports are bl ocked , fluid from pressu re
MASTER CYLINDER ASSEMBLY TO MASTER-VAC bleeder will flow through the replenishing port s behing
primary cups and then over the piston s and lip of primary
NOTE: Th e maste r cylinder push rod has been factory set
cups to wheel cy linders or ca lipers. Hence bl eed ing th e
and can not be altered (Fig . 5-21 ). Follow the procedu re
system does not indicate that th e co mpensating ports are
below to ensure co rrect master cylinder to master-vac
clear.
in stall ation .
05-14 BRAKES
NOTES
BRAKES 05-15
MASTER-VAC TANDEM BOOSTER appli cati on is obtained , th e atm os ph eri c port 'A' remai ns
open until the load on the peda l is red uced .
OPERATION No Power Condition
Released Position (Fig. 5-14) It should be noted in th e case of engine fai lure and con-
sequ ent loss of eng in e vacuum at least one full powe r brake
With the engine running and brakes released , vac uum from applicati on or seve ral partial brake appli ca ti ons may be
th e engine intake manifold is admitted to th e front c hamber mad e from th e vac uum res erve in th e Master-vac. In th e
of th e front d iap hragm of th e Master-vac ; through th e case of no vac uum in the power system, th e brakes can be
vacuum hose and c heck va lve then to th e front c hamber ap pl ied in th e co nven ti ona l manner by applying mo re
of th e rear diaphragm through the cen tre of th e va lve body . physical effort to th e brake pedal.
With the Master-vac in the released position , th e atmo-
sph eri c port 'A' is c losed and the vac uum po rt 'V' is open
to admit vac uum through the passage in th e centre of th e DISASSEMBLY (Fig. 5-17)
va lve body and va lve to th e rea r c hambers of both
diaphragm s. 1. Rem ove master cylind er from master-vac .
With vac uum presen t in th e fron t and rea r c hambers o f both 2. Sc rib e a line ac ross th e front and rea r shel ls to ensure
diaphragm s, th e diaphrag ms are balan ced or suspe nd ed co rrect re-assembly .
in vacuum . The re tu rn sp ring hold s th e diaphragms in th e 3. Remove vacu um c hec k va lve and gro mm et from front
released pos ition . shell.
4. Remove dust cove r and felt air silen cer from valve
body and input push rod assemb ly.
Applied Position (Fig. 5-15) 5. Remove output push rod and seal from front shell.
6. Place master-vac in disassemb ly tool 5A8 with rea r
Upon appli cation of th e brakes , the valve rod and plunger shell stu ds in holes in base of tool. Place bar wrench
move into th e valve body to c lose the vac uum port 'V' and and ada ptor ove r stud s in front shell. (Fig . 5- 18) .
open th e atm os pheric port 'A' to adm it air through th e air
clean er and va lve to th e rear chambers of both diaph - 7. Tighten centre bolt suffi ciently to free loc k at rim of
ragm s. front shell.
With vacuum present in th e front c hambers and atmo - 8. Turn bar wrenc h anti -c lockwise so th at th e cutouts in
sph eri c pressure in th e rea r c hambers, a force is developed front shell ali gn with indentation s of rear shell .
on th e diaph ragms and pressure plates to move th e va lve NOTE: Shell s sho uld begin to separate as cen tre bolt is
body assemb ly, hy<;Jraulic push rod and master cyl ind er loosened ; if not, check ali gnment of c utouts and in -
pi stons to c lose the compen sating ports and fo rce fluid den tati ons. Tap front shell lightly wi th rubb er or pl asti c
und er pressure to th e front and rear wheel cylinde rs to faced mallet to break bond between th e diaphragm and
actuate th e brakes. shells .
As th e pressure is developed in th e master cylind er a 9. Unscrew ce ntre bolt suffi ciently to remove front shell
co unter force act in g through th e hydraulic push rod and and return spri ng. Remove unit from disassembly too l.
reacti on di sc against the va lve body assembly and va lve 1 0. Remove reacti on disc hub, reacti on disc, reaction
plun ger sets up a reaction force opposing th ·9 force applied plun ger and sea l from in sid e of vavle body.
to th e va lve rod and plun ge r. This reacti on force tend s to 11 . Pu sh on input rod to remove valve body and d iaph -
close th e atm osp heri c port 'A' and re-open th e vac uum ragms assembly from rear shell. A screwdriver may
port 'V' . have to be used to lever the centre plate past th e
Since thi s force is in op position to the force applied to th e indentati ons in th e rear shell.
brake pedal by th e driver it gives the driver a 'feel ' of th e 12. Remove ci rclip from va lve plunger and withdraw th e
amount of brake applied . The proportion of reacti ve force input va lve rod assembly from valve body .
appli ed to th e va lve plunger through th e reacti on disc is 13. Whil e hold in g th e valve body assembly fi rml y by hand
designed into th e Master-vac to ensure maximum power on a bench with front diaphrag m fac in g downward s,
co nsistent with maintaining pedal fee l. Th e reaction force pu ll with other hand the rea r diaphrag m upward s to
is in direc t proporti on to th e hydrauli c press ure devel oped sepa rate it from th e va lve body.
with th e brake sys tem.
14. Remove diaphragm pl ate from valve body .
15. Slid e th e centre pl ate from valve body .
Holding Position (Fig. 5-16) 16. Remove front diaphragm from va lve body in sam e
manner as rear diaphragm.
Durin g th e brake appli cation th e reacti on against th e valve 1 7. Remove front pressure pla te.
plun ge r is co nstantly tendin g to c lose th e atmospheri c port 18. In spect seals in rear shell and centre plate. Remove
'A' and re-o pen th e va cuum po rt 'V'. With both port s only if nec essary and if new seals are availabl e.
closed , th e Master-vac is said to be in the holding pos iti on
and any deg ree of brake appli cati on obtained will be held CLEANING AND INSPECTION
until eith er th e atm os ph eri c port 'A' is reopened by an
inc rease in pedal load to further in c rease the brake ap - 1. Clean all metal parts in de -greasin g so lve nt.
pli ca ti on, or by a decrea se in pedal load to re -o pen th e 2. Was h pl asti c and rubb er parts in c lean meth ylated
vac uum port 'V' to decrea se brake application . Wh en th e spirits.
load app li ed to th e brake pedal is held constant , th e valve 3. Using compressed air, blow out all passag es and valve
return s to its holding pos ition. However, wh en full power holes .
05-16 BRAKES
V ACUUM PORT V (O PEN)
ATMOSPHERIC PORT A
(CLOSED)
Released Position
Figure 5-14
VACUUM PORT V (C LO SED)
A TM OSPHER IC PORT A
(OPEN)
Applied Position
Figure 5-15
BRAKES 05-17
VACUUM PORT V (CLOSED )
ATMOSPHERIC PORT A
(CLOSED)
Holding Position
Figure 5-16
4. If ru st has formed on any of th e metal pressings, polish 4. Stand the large end of valve body on benc h, then
clean with fin e emery cloth and wash with methy lated locate front pressure plate in position on valve body.
spirits. 5. Lightly smear the diaphragm locating groove in va lve
5. In spec t diaph ragm s for wear and damage, and replace body and d iaphragm inne r bead with HN114 7 grease.
if necessary . 6. Assemble diaphragm ove r valve body and seat inn er
6. In spect plasti c va lve body for c racks, damage and bead into location groove betwwen pressure plate and
excessive wear . Ni cks and burrs on seal bearing va lve body using thumb and forefinger. (Fig. 5-20)
surfaces will resu lt in damage to th e seals and wil l Ensure diaphragm bead co rrectly seats in locati on
cause air leaks and errati c operation of unit. Replace groove.
if necessary . 7. Light ly smear the larger bea ring surface of va lve body
7. If stud s are loose in shell s, replace the shel ls. Do not with HN 114 7 grease and assembly centre plate and
attempt to reclaim by welding , as th e heat may distort seal on to valve body.
th e shell s res ulting in errati c operation of unit.
ASSEMBLY CAUTION: Ensure that the rubber sealing lip of the large
seal is not damaged or turned over when assembling over
NOTE : Be careful durin g assembly procedure that no
th e air holes in large bearing diame ter of valve body
grease or min eral oil co mes into co ntact with rubber parts
of Master-Vac unit. Smea r all rubb er parts with brake fluid
or rubber grease to G M Specifi cation HN 114 7 lubrica nt 8. Assemble rear pressure plate and diaphragm in sa me
pri or to in stallati on. If unit is to be sto red for any length of manner as front diap hragm.
tim e aft er overhaul , rubb er grease should be applied lib - 9. Locate outer bead of rea r diaphragm on to th e cen tre
erally to rubb er parts and sides of push rod , both on shaft plate.
and reacti on fa ce. 1 0. Lightly smea r va lve rod and plun ge r assembly with
1. Lightly smear th e rear and centre plate sea ls with HN114 7 grease and assemble into bore of va lve body.
rubber grease to GM Specification HN114 7. Retain in position with circ lip fitt ed from op pos ite end
2. Support th e rear shell on wooden block and carefully of va lve body.
drive in rea r seal (pla sti c bearing ring side first) using
suitabl e in stall er. CAUTION: Ensure circlip seals co rrectly into groo ve on end
3. Support th e centre plate on wooden bl oc k wi th th e seal of plunger assembly
lead in edge of hole fa cing upward s. Carefully drive in 11 . Lightly smea r the small er bearing surface of th e va lve
th e centre seal (rubb er side first) using suitab le in - body with HN 114 7 grease and the ourside beads of
stall er. front and rea r d iaphragm s.
0
0'1
I
CHECK VALVE ASM .

"""'
(X)
CJ
b~
CHECK VALVE GROMME T
:::c
PUSH ROD ,;
l>
RETAINER,
PUSH ROD
{ / / ;, - ' REACTION DISC
FRONT
"enm
I
DIAPHRAGM
SEAL
RETURN
t~lea~,~;E~W ~p
SPR ING REACTION { SEAL
PUSH ROD SEAL

SUPPORT PLATE
PUSH ROD ASM.
FRONT SHELL
& STUDS
REACTION DISC
HUB
VALVE BODY
VALVE ROD
PLUNGER ASM.
DIAPHRAGM
PLATE Disassembly
Fi gure 5-17
BRAKES 05-19
Figure 5-1 9
Removing Rear Diaphragm
Figure 5-18
Seperating Master-Vac Unit (Typical)
12. Carefully assemble valve body assembly into rear

shell, and through rear seal. Ensure outer bead of rear
diaphragm remains located on centre plate.
13. Place rear shell assembly into assembly tool.
14. Smear with rubber grease the sq uare sectioned rubber
seal ring , and fit into bore at hexagon end of reaction
disc hub .
15. Lightly smea r the outside of the reaction plunger wiih
HN 114 7 grease and assemble into the centre bore of
reaction disc hub .
16. Ca reful ly lower (la rg e end first) the reaction disc hu b
into position in th e cent re of valve body, ensureing
reaction plunger does not fall out.
17. Lightly smear rubber reaction disc with HN1147
grease and install into reaction disc hub, ensuring
Figure 5-20
small rubber protrusion of disc faces reaction plunger.
Assembling Diaphragm
18. Assemble return spring over and against shoulder of
reaction disc hub .
19. Locate front shell over return spring with scribe marks
mad e at disassembly adjacent to each other. Place bar 24. Assemble master cylinder push rod sea l suppo rt into
wren ch over studs in front shell. Align cut outs in front rubber seal and install over push rod into front shel l
shell with indentations in rear shell, then tighten centre recess.
bolt of th e assembly tool and turn bar c lockwise suf- 25. Install check valve grommet in front shell and in se rt
fi cien tly to lock shells together. check valve in grommet.
Loosen centre bolt and remove master-vac from as-
sembly tool .
20. Install foam filter into bore of valve body.
21. In stall felt filter over push rod and against valve body.
22. In stall dust cover over felt filter and valve body.
23 . Lightly smear th e master cylinder push rod with
HN 114 7, then ca refully lower through front shel l and
positi on in reaction disc hub against reaction disc .
05-20 BRAKES
MASTER CYLINDER ASSEMBLY TO MASTER-VAC pensatin g ports , then th ey are clear. If the primary cups
NOTE: The master cylinder push rod has been fa ctory set
overlap th e comp ensating ports th ere will be no flow of air
and ca nn ot be alt ered . (Fig . 5-2 1). Foll ow the proced ure or fluid th ro ugh th e compensa ting ports wh en th e uni t is
below to ensure co rrect master cylinder to master-vac st roked.
in stallati on . NOTE: If thi s co nditi on exists do not use.
Failure to c lea r th e co mpensatin g po rts in th e rel eased
Install master cylind er to master-vac unit, spring wash ers
pos iti on, traps fluid in fro nt of th e primary c ups and holds
and nuts and ti ghten to 13 .5 Nm torqu e.
press ure in the hydraul ic lines causing wh ee l drag . If the
After assemb ly of th e master cylinder to master-vac, th e com pensatin g ports are blocked , fluid from pressure
primary cups of th e master cylind er must be clea r of th e bl eeder will flow through th e replenishing port s behind
co mp ensatin g holes wh en th e unit is in th e released primary cups and then over th e piston s and lip of th e
position , th is can be chec ked by partially fillin g th e res - primary cups to wheel cylinde rs or cal ipers. Hence
ervoir and then strokin g th e master-vac. bleeding the system does not indi cate that th e co m-
If air bubbles ap pea r or th e fluid spurts from th e com - pensating ports are clear.
1-4- - - - - - 19 1.5±0.7 mm - - -- - - -.-.
--...._ I
I
II
I
I
r-
I I
0.58 mm
0. 84 mm--~
LJ----
Figure 5-21
BRAKES 05-21
DISC CALIPER: (FRONT AND REAR) cyli nd er supply tank - top up to co rrec t fluid leve l
(6 mm be! ow rim o f reservoir) with ap proved hydrauli c
brake fl uid - G M 4653 M, Typ e 450.
DESCRIPTION
The caliper (Fig . 5-22) co nsists of two ma in co mponents,
an SG iron anc hor pl ate and a light alloy housing .
CALIPER OVERHAUL (FRONT AND REAR)
The an c hor plate is rigidly fixed to th e stee ring knuckle
whil st th e ho usin g slid es within the anchor plate by means
Removal
o f two guid e p in s bolted to the housing. Rubber boo ts a re
fitt ed to th e gui de pins to kee p out dirt and fo reign ma tt er. 1. Di sc harge th e brake flui d via th e caliper b leed sc rew .
Th e ca liper ope ra tes on th e singl e pi ston principl e with the 2. Disconnect th e brake hose from th e caliper housin g
housing in co rp o ratin g the hydraulic pi ston and seal. When and discard sealing gas kets.
hydrauli c press ure is applied , th e sing le piston forces the 3. Detach th e c aliper ho using from th e mounting brac ket.
inner pad aga in st th e di sc with the housing reacting to pu ll (It is no t necessa ry to remove th e mountin g bracke t
th e outer pad towards th e disc . The press ure on both sides from the ve hi c le fo r normal ca lip er ove rhaul.
o f th e d isc is th en equal. 4. Withdraw guide pins and rubb er boo ts from mounting
Wh en th e press ure is released the pi ston sea l retra c ts the bracket.
pi ston a small amount , which allows th e moving parts to
relax sufficien tly fo r pads to remain in c lose proximity to the Disassembly
disc with o ut dragging . Adjustment fo r wear is automati c. 1. Pac k a clean piece o f clo th b etween th e outer end o f
Inn er and out er pads are identical , eac h pad inc o rporates the piston and ho using outboa rd legs and appl y ai r
pressure at the brake hose inl et po rt to ej ec t th e pi ston.
a torsional spring to eliminate ho usin g and pad rattles .
CAUTION: Apply light air pressure initially and pro-
gressively increase until piston is forced out of th e bore.
PAD REPLACEMENT (FRONT AND REAR ) This preca ution is advisa ble to avoid physical injury, as the
piston may de velop co nsiderable force due to th e air
Removal pressure.
2. Remove the rubb er boo t from th e bore .
1. Rem ove two third s of the total fluid ca pacity from the
appro priate sys tem Master Cylinder reservoir. Crack 3. The seal can now be removed from th e bore, but take
th e fron t line co nn ec ti on a t th e Master Cylinder and care not to damag e the bore o r seal loca ting groove.
bleed down th e fluid level. Do no t rem ove th e brake
lin e or compl etely empty rese rvoir o r it will be Cleaning
necessary to b-l eed th e hydrauli c system . Di sca rd the 1. Clea n all metal parts th o ro ugh ly with methylated
b rake fluid rem oved . DO NOT ATTEMPT TO REUSE . spirits . Use c lea n dry co mpressed air to d ry o ff th e
NOTE: Rem ova l o f th e fluid is necessa ry to prevent res - parts .
ervoir ove rfl ow wh en th e ca lip er piston is pushed back in 2. Examine th e bore and pi sto n c a refull y for signs of
its bore during pad repl ace m ent. damage , abrasion , sc uff ing o r co rros ion. RENEW THE
2. Jac k up th e ca r suppo rt on stand s and rem ove th e road PISTON IF ANY OF THESE FACTORS EXIST OR IF
wh ee ls. DO NOT PLACE JACK OR STAND S UNDER THERE IS A NY DOUBT ON ITS CONDITION . If th e bore
VEHICLE CO NTROL ARM .Rem ove th e housing re- is unserviceabl e a new ho using mu st be fitt ed .
tainin g bolts. Th e ho using can now be lifted from o ver
th e mounting bracket and disc. HANG CALIPER FROM Assembly
VEH ICLE WITH WIRE HOOK . DO NOT ALLOW BRAKE 1. Lubricate cylinder bo re with brake flui d and fit new
HOSE TO TAKE THE WEIGHT OF THE CALIPER . seal into th e g roove in th e bore , ensurin g th e sea l is
3. Check th e gui de pin s fo r freedom o f movem ent also no t twi sted and is fu lly sea tecl in th e groove.
the co nditi on o f th e rubber boo ts. If the guid e pin s 2. Fit new bo ot into th e o uter g roove o f th e bo re, ensuring
cannot be moved freely by hand , these sho uld b e fl ang e of boot is squarely and firmly seated in th e
removed and c leaned . groove.
3. Lubri ca te th e outsid e diam eter o f th e p is ton with brake
Installation
fluid and in stali into th e bo re. Spread the boo t ove r th e
1. Befo re refitting th e guid e pin s to th e anc ho r plate th ey pi ston as the piston is in stall ed, . takin g ca re no t to
are to be lubri ca ted with a si licone typ e grease 'Dow d isturb the boo t in the g roove. Apply steady pressure
Co rnin g No. 44 ' or equiva lent. IT IS ES SENTIAL THAT BY HAND to th e pi ston and press until th e pi ston is
G REASE BE NON MINERAL OIL BASED OR RUBBER full y sea ted in th e bore . Ens ure th e o uter lip of th e boo t
SWELL WI LL RE SULT IF IN CO RRECT GREASE IS is loca ted in th e groove of th e pi ston. Replace bl eed
USED . sc rew.
2. Press th e pi ston by hand , eve nly into the bo re o f th e
housin g until th e pi ston is fu lly b o ttomed . Replace
3. In stall new pad s into th e m o unting bracket. Pos iti on 1. Fit guide pin asse mbly. Lubri ca te bo th gu ide pin s with
th e ca liper housing ove r the di sc and pads . a si li co ne type g rease 'Dow Co rnin g No . 44' o r
4. Fit bol ts and wa she r assembl ies to ho using and ti g ht en eq uivalent.
in to guid es. 2. Fit rubber dust co vers over gui de pins.
5. Depress th e brake peda l seve ral tim es to actuate th e 3. In sert guide pin s into mouting brac ket and fit rubber
pi ston to b rin g th e pad assemblies into position dust cove rs to guide pin grooves and moun ti ng
against th e d isc. Check the fluid level in the master brac ket.
0
~
U1
•
I
1\.)
1\.)
/~ ~ I -----&f= BOLT - SELF LOCKING I o:J

-_ .. ·
::c
BOOT - GUIDE PIN l>
1 ,._ ~- ..
"m
BLEE D SCR EW I
HOUSING CJ)
GUIDE PI N
ANC HOR PLAT E
PI STO N
BOOT - PI ST ON
~ L
Figure 5-22
Slim line Colette Caliper
BRAKES 05-23
4. If necessary, fit new pads then position housing as- THE DISC BRAKING SURFACES MUST MEET
sembly over pads and bracket. Re-fit screws through
housing into guide pins and tighten securely. THE FOLLOWING SPECIFICATIONS
5. Re-connect the brake hose with new copper gaskets
ensuring that the hose is located correctly and torque
attaching bolt to 40-51 Nm (Fig. 5-23 front, 5-25
rear).
6. Bleed the appropriate system, then depress the brake
pedal several times to bring the pads into position
against the disc. Recheck the fluid in the master
cylinder reservoir and top up if necessary.
BRAKE DISC
REMOVA L MOUNT ON
1. Jack up vehicle, support on stands and remove whee ls. BEAR ING CUPS
DO NOT JACK OR SUPPORT VEHICLE FROM UNDER
LOWER CONTROL ARM.
2. Remove ca liper mounting b racket attaching bolts and
hang caliper from vehicle using wire hook. DO NOT
ALLOW CALIPER TO HANG BY BRAKE HOSE . Figure A
3. (a) Front Disc- Remove split pin , nut and wi thd raw Hub and Disc Mounting (Typical )
disc and hub assembly.
3. (b) Rear Disc- Slide disc off park bra ke and studs.
(Fig. 5-25) A. Both surfaces must be square with bearing cup
centreline within .1 mm T.I.R.
Mount the hub and disc to the lathe on the bearing
REPLACEMENT cups - Do not mount on hub surface.
1. Reverse removal operations torqueing caliper moun-
ting bolts to 70-85Nm front and 40-51 Nm rear. Adjust
front disc and hub assembly as outlined under 'Wheel
Bearing Adjustment' in Section 3.
DISC BRAKE REFIN ISHING

Brake discs can be refinished if precision equipment is
available and a few simple rules are followed. The first th ing
to do is to determ ine which of the following will need to be
done.
Resurface-Recondition or Replace
Resurface
With a flat sanding disc (with disc rotating) if scoring is light
or if the disc surface has severe rust scale.
Recondition
If scoring is deep or if runout , thickness variation, flatness
and parallelism are out of specification. Scoring of the
brake disc surfaces not exceeding .015 inch in depth,
which may result from normal use, is not detrimental to
b rake operation.
NOTE: Both sides of the disc must be treated in the same
manner. If one side needs resurfacing or reconditioning the
opposite side should be treated in the same manner. Figure B
Disc Directional Finish (Typical )
Replace
If th e disc cannot be reconditioned to bring it within
specifications and meet the minimum thickness B. Both surfaces must be free of scratch marks and
speci fication after reconditioning. porosity.
WARNING : THE NUMBER CAST INTO THE BRAKE HUB IS Th is disc has a directional finish which is no t des ira bl e
A DISCARD DIMENSION NOT A REFINISH DIMENSION. as a 'ref inished' p roduct
05-24 BRAKES
E. Must be parallel with each other within .076mm T.I.R.

when checked radially.
To prevent pa rallel tape r that co ul d wea r pads on an
angle.
Figure C
Disc Non-Directional Finish (Typical)
MARK D ISC
RUN OUT .1mm
C. Finish is to be 0.4 to 2.0 microns and must not be W ITH CHALK
WITH MAXIMUM
circumferential (directional). EVERY 30 °
OF .03mm IN 30°
This disc has a preferred non -directional finish that is
ac hi eved with a flat sanding disc.
Figure F
Checking Lateral Run-Out (Typical)
F. When mounted on bearing cups , lateral run-out must

not exceed .1 mm T.I.R. and maximum rate of change
must not exceed .03 mm in 30 degrees.
To preven t disc 'wobb le' that co ul d kn oc k th e pi ston
back into the calipe r bore - increased peda l travel
wo uld then res ult .
THESE SURFACES TO
BE FLAT W ITHIN
.05mm WITH R ES PECT
T O BEARING CUPS
FigureD
Checking Surface Flatness (Typical)
D. Both surfaces must be flat within .OSmm T.I.R.

To prevent surface tape r tha t co ul d wear pads on an
angle .
+ .0 28m m -. 015m m
TOTA L VAR I AT I ON =.0 13mm

II I
Figure G
Checking Circumferential Thickness Variation (Typical)
TAPER VAR I AT I ON
MU ST NOT EXCE ED G. Total circumferential thickness variation at any radius
. 076mm must not exceed .013 mm in 360 degrees.
To p revent brake pedal pul sati on. Place in dica tors
oppos ite eac h oth er and set to ze ro. As d isc is ro tated
Figure E watch each ind icator for proper tolerance. A mi -
Checking Surface Parallelism (Typical ) crometer co uld be used for th is chec k.
BRAKES 05-25
I. Surface 'B' must be flat within .08 mm and parallel with

.08 mm T.I.R. relative to surface 'A'.
To prevent wh eel wobbl e.
Surface 'C' must be square to surface 'A ' within
.05 mm T.I.R. and have a circular runout not exceeding
.08 mm.
To allow effi c ient c ontac t of park brake shoe lining s.
Each brake surface of the disc must be flat within
.13 mm and parallel to surface 'A' within .13 mm.
To prevent taper wear on pads and di sc wobbl e.
Braking surface finish on the disc surface is .60 to
1.25 microns and for the park brake surface 20
13 2.0 135 .4 microns.
to to
133 .1 m m 135.5mm
PAD TO CHAMFER
CLEARANCE:
1.3 mm M i n.
2.5mm Max.
Figure H
1
Disc Outer Diameter Chamfer Machining
H. The brake disc outer diameter chamfer must be

45 degrees x 1mm maximum with a pad to chamfer
clearance of 1.3 mm Min. to 2.5 mm Max.
To preven t the rma l stress crac ki ng at th e top of th e
disc .
SU RFACE 'C' MU ST BE SQ U A R E
TO SU RFACE 'A' WI T H I N .0 5 T .I .R.
& CI RC U LAR R UN OU T N OT T O
EXCEED .08mm.
'C'
- 'A'
SURFACE 'B' T O
BE FLAT W IT HIN
.08mm & PARA LL EL
W ITHIN .0 8 mmT. I.R .
RE L A T IVE T O
SU RFACE ' A'
EAC H SU RFACE ~ RATE OF CH A N GE MU ST N OT

MUST BE FLAT EXCEED .03mm iN 30% R OT A TI O N
WITHI N .13mm &
PARA LL EL TO
SU RFACE 'A' WITH I N .13mm
Figure I
Rear Brake Disc Surface Checks.
0
U1
I
1\)
0')
UN I ON 7 OJ
B END CLIP T O RE T A IN PIPE :0
• GROMMET )>
~~ 2PLACES
"enm
.~~ ~C:> l~L ;r v~,._/~
SEA L ~
-~·7.}' ~ . 1~)Irr,_.!{_ . ~~ • - -~
~__J ·~~~C
~~
,-
~- _:. ,o ~ -. .__ '(,H) /
\ d
t
-
ID ~~
·- --(?,i:l I' R.H . 6 CY L. EXC . JMB 1 · LJ
~ ~ -~ ~ ~AI C::·:a ~~
• L .H. 8 CY L ., 6 CY L & JMS -< c' · f ,
?; fl: ~ ... ~ v"' . I@'I )
~ /~~~j.t,, ?.·~
/I I I I I <)
(
::):<.~ I ;' ~' "'j •0l@ c:qr- £

I A .. -
~~
1
\ (f=~. ~·
~ : .~~.,~/~
1
"'-. "- GASKETS
(Q· ~~ /[).~- // '\

L & B R AK EHO SETO
CA LIPER BO L T
~:;:? ~ )) '-ffi
~-~ ~ ~/ ,. ~n- ~'·~ '
2 PL ACE S
'\ ..........~ :.>~ >:;:()'~ ·s

~ ~r)
. ..... ._Jj ' ' t/'.. INSU
BV LL ATOR
BVX
BEND T A NG O V ERPI PE _
ON IN STA LLA TI ON
......-;:/
\ /'{..__ .~
~. FOR CO NT INUATI ON '~
~----- ~ A ~~.
'\"\ CLIP ·
O F PI PE RE F ER F I G. 5 - 32 r; PL AC ES
\...._____ ).· ~,\ 0'
~"-.... ~ /j
[r . ~:·M
=-:s--
(•'c~ -"» j~V
• d B END CLIP T O
RETAI N PIPE
;};~~ ...
r-< ~ I SEC TI ON A-A
"'
£ 27-3 4 Nrn
& 70 - 85 N m
ffi 40 - 51 Nm
ffi 20 - 25 Nm
@
Fi gure 5-23
BRAKES 05-27
DRUM BRAKES (8VK & 8VL MODELS) backing plate pads and adj uster with high temp erature
grease to GM Speci fi ca ti on MP 6805.
2. Reverse removal ope rati ons taking care to back off the
MANUAL ADJUSTMENT ad ju ster so th at when brake d rum is fitt ed it will rotate
fr ee ly.
1. Raise rear of vehicle and suppo rt on jack stan ds. 3. Apply brakes at least 1 0-1 5 tim es and proc eed from
2. Apply brake pedal 8-1 0 tim es firmly . step 3 of DRUM BRAKE - MANUAL ADJUSTMENT as
3. Place park brake on third notc h from full y released previously described .
position .
4. Adj ust park brake relay rod until slight drag is felt at
wheel.
WHEEL CYLINDER
5. Release park brake , c hec k that wheels rotate free ly
and lower vehi c le.
REMOVAL
BRAKE SHOES 1. Jac k up vehi cle and support it on jack stands and
remove wh ee ls .
NOTE: Shoe and lining assemblies mu st be repla ced in
sets, th at is both primary shoes, both seco ndary shoes or 2. Disconnect brake sys tem hydrauli c lin e fro m wheel
both co mplete sid es. cylinder.
3. Remove brake shoes as outlin ed und er heading 'B rak e
Removal Shoes - Removal' in this section .
1. Raise rear of vehi cle and support on jac k stand s and 4. Remove the wheel cylinder to backi ng plate attac hing
remove wheels . bolts and washe rs, remove wh eel cylind er.
2. Loose n off park brake ad ju stmen t.
DISASSEMBLY (Fig. 5-26)
3. Remove brake drum s. If drums are worn or lipp ed,
remove rubber plug from bac king plate and usin g a 1. Remove th e wheel cylind er clamp and remove rubber
screwdriver, push th e park brake actuating leve r boots , piston s, cups and sp ring with cup expa nders.
ou twards, so that stop pin on leve r clea rs brake shoe 2. Remove bleeder valve.
web. Brake shoes will co ntract, allowing drum rem oval.
4. Install wheel cylind er clamps. INSPECTION
5. Disconnec t park brake cab le from leve r. 1. Wa sh all parts in clean approved hydraulic brake fluid .
6. Remove self adjuster and lower brake shoe retractor
springs . CAUTION: Do not use petrol, kerosene or any other
cleaning fluid that might contain even a trace of mineral oil.
7. Remove hold down springs and pins and push rod
adjus ter assembl y. 2. Inspec t th e cylinder bore for sco res, deep sc ratches or
corros ion. Light sc rat ches and sli ghtly co rroded spots
8. Spread shoes to c lea r wheel cy lind er pu sh rods, lift
in the cylinder bore may be poli shed with c roc us c loth
shoes off th e ancho r.
or No. 400 'Wet or Dry ' paper. Do not use eme ry clo th
9. Disassemb le adjuster and park brake leve rs from or sandpaper. If th e sc rat ches or co rroded spots are
shoes if necessary. too deep to be poli shed sati sfa ctorily with croc us cloth ,
the cy lind er should be repla ced, sin ce honing is not
To Replace Brake Linings recommended .
1. Remove rivets , was h shoes in clea nin g so lvent and buff 3. Chec k the rubber cups for wea r or damage, repla ce if
wi th wi re brush . necessary .
2. Check drum s to determine whether ove rsize linings are 4. Check th e pi stons for wear or damage and for
req uired. clearan ce in th e cyli nd er (Fig. 5-27). This cleara nce
3. Install new linings on shoes usin g a suitabl e machine shou ld be wi thi n the range of .05-.13 mm.
to spread rivets . Primary and Seco ndary lining s are
5. Check th e fit of th e boots on the ends of the cy lind er.
interchangeable. If boots are loose fitting or damaged they sho uld be
NOTE: It is good practice to use a brake shoe lining clamp replaced .
to force lining against shoe, this eliminates any uneven
contact between lining and shoe to prevent ineffi c ient ASSEMBLY
sq uea ling brakes. For iden tifi ca ti on of parts refer (Fig. 5-26) Dip th e pistons,
cups and spring in clean brake fluid before assembly and
Inspection use ca re to avoid damag ing th e edges of th e pi ston cups.
1. Disassemble adjuster mechanism and check for burrs , In stall wheel cylinder clamp, to fa ci litat e instal lati on of
damaged or worn threads or adjuster teeth . Nut must wheel cylin der assemb ly to bac kin g plate.
turn fr ee ly by hand .
2. Check ad juster and park brake ac tuating leve rs for INSTALLATION
wear or damage. 1. Install wheel cylinder on th e brake backing plate and
3. Check all springs and pins for wear or damage. co nnect th e brake lin e.
4. Insure backing plat e pads are free of burrs . 2. Install brake shoes as outlin ed un der head ing 'B rake
5. Check park brake cab le for fr ee operati on. Shoe - Replace .'
3. In stall brake d rum , wheel .
Replace 4. Bl eed th e hydrauli c system and adjust b rakes . Road
1. Lightly smear all metal to metal parts , in cluding test ve hi cle for brake performan ce.
0
CJ1
I
I\)
()0
m
::c
)>
SHOE RETAIN I NG
lt] "m
CJ)
SPRING SECTION B-B

BACKING PLATES
PUSH ROD A
I
_l ~~
[~
• BRAKESHOE
) ; ; "" / LINING ASSE:BLY WHEEL CY LI I\J DE ~ 0 ' .CL:i+--
~ ()
+~
TORQUE
1\ / ~
B-
I
--I-::-? __,
I J
~c 10 It \ ___ 8
'-~
~<
\[)
'J• 85-11.0Nm
~ ~I-·~ d
NUTAC
LEVER TUAT I NG #
.
~ t~ ~ l-- · r::._ ~ J
\-~I
~ I 0 ---~STOPPIN
'
I - . "--~· v--' .0:1 - I ? · - ,----<> j'
DOWN ~'
I '·_
HOLD
I
NUT ~~ PI N ~ ._ ,
ACTUATI NG 1 ' --- II 1 0 C- -
· _ HOLD DOWN - i
'._)
I "'- ' C SPRING
SPR I NG
I. ,.
~-~
. ~~... ~~
PLUG
\ {; '---....
·~ \~
Go 1
. ~
')
~
~r-r-
ARK BRAKE
. -+_f'---;;./''----' pLEVER
T ENSION SPR I NG
I
j__
I
A SECTION A-A
LH - S H OWN
RH - O PP OSITE
Figure 5-24
Rear Drum Brake (8VK & 8VL)
FOR I NSTA LL A TI O N OF 1
- H A N D BRA K E CA BLE
REAR BR A KE LINE S
1
REFER FIG. 5-32 . ,'
""' M OUNTI NG BRACKET

I
FOR I NSTALLATION OF G~ ~ - I ~
"' A :_.@ ~
"
---- £
TE NSION SPRING REF ER 1 ~~
~~ ____.. ~ ~
:. y, ,
FRONT OF F I G . 5-29 · __ -! _ _ ,.,
CAR ~/. ) ' ----"
. ,-1''~.-
I -
1
~J I
CA LIPE R&BRAK E
SHOE SUPPORT ~ ~-- '-r;:
- - ~ ' L>-<.'
- J
\
9__
~
/ ::.-4 "'-
""" "_, ___,_...-- '« z.. I '- ' )
,l\ ~
J
I
c;;?\\~\ ~.:.:;.-..:---- -
--l
~ ··-~ -@ ~
--- ' d',
II~--~ "\
c:fc0
\ -::;, 1\ &l' J ~H I
I
~~ \ \ ~ \ ~ ~ _:---~ ~ (~ ~8:~&
.... (.,,.-'' \ ·. ) ! - - ·t ' ,,,
;( \~J\ \ ~~- <~ ~

---- :.. (
( ~- ' \
~~- )
~
.)i?S~/
_>
f· -._,
\\
\ i 11 \\ \ ~ ~ BRAKE HOSE
(gc.--- ~---::~. _," '
' \'\ ·~
~~---!L
\
I
.
\
/ ~~
~ €- '
'\ I .::::-::-
-~-:::::-
~
. :.-- -,
~ '
,;
f_,.
\~-\~~) :
__..... ......._ "" ! • Y'}~-
L DISC / DRUM /CJ ,~
ASSEMBL Y
GASK ETS .
-~~-
/2:, 8 - 1 1 Nm
& 55 - 70 NM
~
-- - -~ m
JJ
ffi 27 - 34 Nm )>
&
LG
12-16Nm
8-10,6Nm
"m
(J)
0
CJ1
I
Figure 5-25 1\)
(0
Rear Disc Brakes
05-30 BRAKES
Grooved Drum
1 If the brake linings are a little worn and the drum is grooved,
·~
the drum should be machined just enough to remove the
3 grooves, and the ridges in the linings should be lightly
removed with a lining grinder.
If the brake linings are more than half worn, but do not need
replacement, the drum should be polished with fine emery
6
cloth. At this stage, eliminating the grooves in the drum and
1. BOOT smoothing the ridges on the lining would necessitate the
2. PISTON removal of too much metal and lining , while if left alone, the
3. CUP 3 grooves and ridges match and satisfactory service can be
4. EXPANDER
5. SPRING 2 obtained. If the shoe and lining assemblies are to be re-
6. BODY placed, a grooved drum if used with new linings will not only
1
7. VALVE wear the lining but will make it difficult, if not impossible,
I to obtain efficient brake performance.
Out of Round Drum

An out-of-round drum makes accurate brake shoe ad-
Figure 5-26 justment impossible and is likely to cause excessive wear
Exploded View of Brake Wheel Cylinder of ot her parts of the brake mechanism due to its eccentric
action. An out-of-round drum can also cause severe ir-
regular lyre tread wear.
A drum that is more than .254 mm out-of-round on th e
diameter is unfit for service and should be machined .
Out-of-round , as well as taper and wear can be accu rately
measured with an inside micrometer fitted with extension
rods.
When measuring a drum for out-of-round, taper and wear,
take measurement at the inner and out edges of machined
surface and at right angles to each other.
RECONDITIONING
If the drum is to be machined for use with only slightly worn
linings, remove only enough metal to obtain a true, smooth
braking surface. If a drum does not clean up when
machined to a diameter of 230.38 mm it must be replaced.
Removal of more metal will affect dissipation of heat and
may cause distortion of the drum. Standard size shoe and
lining assemblies as serviced will provide satisfactory
operation providing the drum diameter does not exceed
229.36 mm . If the brake drum diameter exceeds this
dimension afte r machining and providing it is within the
Figure 5-27 range of 229.36 mm to 230.38 mm the .762 mm oversize
assemb lies sho ul d be used.
Checking Wheel Cylinder Piston Fit
Brake drums may be refinished either by turning or grin-
ding. Best brake performance is obtained by turning drums
with a very fine feed. Ground and polished drums do not
BRAKE DRUM wear in as readily as turned drums and are more likely to
cause unequal braking when new. After turning , the turning
INSPECTION 'peaks' or high spots should be removed with fine emery
Whenever brake drums are removed they should be th o- cloth. To ensure maximum lining life, the refinished braking
ro ughly cleaned and inspected for cracks, scores, deep surface must be smooth and free from chatter or tool
grooves and out of round. Any of these conditions must be marks.
co rrec ted since they can impair the efficiency of brake Out-of-round of the brake drum refinished surface must not
operation and also cause premature failure of other parts. exceed .127 mm total indicator reading . Run -o ut (sideways
wobble) of the open edge of drum must not exceed
Cracked Drum .762 mm
WARNING : A CRACKED DR UM IS UNSAFE FOR FURTHER
SERVICE AND MUST BE REPLACED. DO NOT ATTEMPT Surface Finish
TO WELD A CRACKED DRUM. Surface finish to be 4 to 1 2 microns and must not have
helical machining marks.
Scored Drum
Smooth up any slight scores by polishing with fine emery BRAKE DRUM BALANC E
cloth. Heavy or extensive scoring will cause excessive During manufacture , brake drums are balanced within
brake lining wear and it will be necessary to replace or 5 kg mm by fastening weights , as required , near the rim.
machine the drum in order to true up the braking surface. These weights must not be remov ed.
BRAKES 05-3 1
After drums are turn ed, or if diffic ulty is experi enced in 3. Remove bolts and lift assembly up to remove park
maintaining proper wheel ba lance, it is recommended that brake switc h, lift out hand le assemb ly.
brake drum s be c hec ked for static balan ce. Drum s out of
balan ce more than 5 kg mm should be rep laced . Brake REPLACEMENT
drum s may be chec ked for ba lance on any suitabl e 1. Reverse removal ope rations.
machine.
2. Adjust re lay rod as outlin ed in brake ad justm ent for th e
appropriate brake system.
PARK DRUM BRAKE (8VX AND OPTION

JM8) (Fig. 5-28)
PARK BRAKE CABLE (Figs. 5-29, 30)
ADJUSTMENT
1. Raise rear of veh icle and support on jack stand s.
REMOVAL
2. Place park brake on third notch from full y re leased
1. Rai se vehi cle and place on jac k stand s.
positi on.
2. Di sco nn ect pa rk brake cab le from relay rod .
3. Adj ust brake shoes until they co ntac t th e d rum firmly .
3. Pull outer cable rea rward out of retaining clips and pry
4. Back off adj uster 1 notch and adj ust relay rod to re-
clip down enough to slip cab le between it and fl oo r.
move slack be tween cable slot and actu at in g leve r
(Fig . 5-29)
8VK and 8VL Models
5. Release park brake , wheels should rotate free ly.
a. Remove wh eel and brake drum and disconnect cable
from actuating leve r.
BRAKE SHOES b. Co mpress ca bl e return sp rin g and remove sp lit guide.
c. With draw cab le asse mbly from backing plates and
REMOVAL through clips on control arms .
1. Raise rea r of vehic le and suppo rt on jack stand s.
2. Loose n off park brake adj ustm ent.
avx and option JM8 Models
3. Rem ove road wheel and disc brake ca liper and a. Disconnect return sp ring , unhook ca ble from actuating
mounting brac ket assembly and hang ca liper from lever and remove from backing plate support.
vehi cle usin g wire hook. DO NOT ALLOW CALIPER TO
HANG BY BRAKE· HOSE. REPLACE
1. Reverse removal operati ons and adjust cab le as out-
4. Rem ove Disc/ Drum assembly.
lin ed in brake adj ustm en t for th e appropriate brake
5. Unhook return sp rin g from ac tuatin g lever and di s- system.
co nn ec t park brake cable . (Fig . 5-29).
6. Remove brake shoe return springs .
7. Remove hold down spring s and pin s and rem ove brake
shoe , actuator and adjuster assembly.
INSPECTION BRAKE PEDAL

1. Disassembly adj uster and c heck for burrs, damaged or
worn threads or adjuster teeth. Nut must turn freely by REMOVAL
hand .
1. Remove clip from clevi s pin and wash er and discon-
2. Chec k actu atin g lever, press ure link and pivot for nect master cylinder push rod and stop lamp switch
damage or wear . bracket.
3. Check all sp rin gs and pins for wear or damage. 2. Remove clip ten sion disc and spring clamp from brake
4. Insure backing plate pad s are free of burrs. pedal shaft.
5. Check park brake ca bl e for free operation. 3. Rem ove shaft, lower pedal assemb ly and remove
spri ng and clevis from peda l.
REPLACE
1. Lightly smea r all metal to metal points, including REPLACE
bac kin g plate pads and adj uster with high tem perature 1. Reve rse removal operati ons, lubri ca ti ng all metal to
grease to GM Speci fi ca ti on MP 6805. metal parts with molybond grease.
2. Reverse rem oval operations and adjust brake as 2. Note co rrec t po sition of return spring and loca te end
outlin ed prev iously in thi s sec ti on. of brake pedal shaft .
3. Adjust stop lamp switch so th at brake lights ope rate
when peda l is depressed 15 - 16 mm .
PARK BRAKE HANDLE
REMOVAL
1. Di sco nn ect park brake ca bl e from relay rod.
(Fi g. 5-29)
2. Rem ove co nso le and lift ca rpet to gain access to
handl e mou nting bolts.
0
ACTUAT I N G LE VER
--fb
"'w
I
1\)
PRESSURE LI NK
OJ
::0
- ~. l_ ·v· ~~~~
l>
r.::~-
C -==;::1 '
.
CLEV IS
PI N
,
~ sci
'
I
"enm
SECTION B-B
Al SUPPORT
I
l
"" I
(.
-.---<~
B ~~imt*t~
4
-l-~
I
'
'
. }
RETURN SPR ,NG _3"%J

I ( I HOLD DOWN SPRING
i'
{~;' I I
& PIN
--... . .
( I
-~ ~
'
\
"
'-~ WlT~
.::::~~ T ;:~
/-
I l
----
RETURN SPR,NG ______.- :e-J1-
~--~- ~,
·_..----1-
- \ SHOE & LIN I NG ASS Y ~~J
[_]
\
\A
SECTION A-A
SCR EW
AD JUSTE R
ASSEMB L Y NUT
r SLEEVE
Figure 5-28
Park Drum Brake (8VX & OPT JM8 )
l~ .~ - ~--- 9
~--
GROMMET -------
t
ill 1 1 !
- TENS ION SPRING
~
(N 10 ONLY)
(R. H . SIDE)
,,
j ~ ,- I
1 I
I 1
SECTION D-D
APPLY HN -1068 AROUND
COMPLETE MATING SURFACES
OF BOOT AS SHOWN _/
/ " "-- SLI DER
SECTION A-A I '
BOOT
RELA Y ROD N UT S J
I ""-- SLIDER (L.H .S IDE )
~- EOUA LI SER ON CABLE ASM .

r - SEAL
1 RE T U R N SPR I NG
I
~) I .
-
SPLI T GU I DE - ACTUATI NG
,' ,_, LEVER I
~-~ -{,L5·_:-=
-- _', ] J -- --~~
- - ,.;;; ......... ~~
(
l
~~\ --~
-<J_:f:..:~-
:k ~ -~~- ~ :-/-,
~
~ -- J l
r,:, - -1
~'· ~ ~· ~f
' . -- -
L , . ; . -· L .- .:_ -=
~-
lh-~~J;~~ll U' .
- - -J -~_/
SECTION B-B m
,...,
EX C. 8VX : JM8. SECTioN"'C-C :c
8VX , JMB .
l>
"
m
(/)
L--------------------------------------------------------------~ 0
CJ1
I
Figure 5-29
w
Park Brake Cable Attachment w
0
CJ1
I
w
~
CJ
:0
)>
PARKBRAKE WARNING LAMP

LEAD. r -
\
"-._-")
"m
CJ)
i HN- 1230
RUBBER Sl LE NCER
/-
----v /}~
_.-/'"....,-- ~-
~
---- . 2 PLA CES \ --;0 - ------....._"'--
~""' / ~-{.J?~
~-\-
! L.-~c-- 1\:i -r?
~;;:;~ ~--~o-~.
~ I ---
::s fi _....... _ _) ~/ ~
/"'~~::Yo c
'-- ) J -·
~ -~ - _...?.:/_:---...__ r ~ - )1/' ~~---- -·.-;>U-.. ,-, ~ ' /

~_,.. ~/
~
~-(")...
.~ ~·<--: 53 ----7 ~_Jc:: /

--~
..... ~ ,~
......
-~ ~ '-- 'I'
-~.-~---_,-;/;·~ ~
RETAIN UNDER
EXISTIN G CLIP ~--..:' tl _ ~_J-' .,_:_,
8
'-~~ "'<- -y, )(·-~ --
I "'---- --
>-;...:__ ~ ::::v
'L
~
PARK BRAKE LE V ER
___,... ~-· ---------== - - . .- so
'/f -~"---
ASSY.
-
~&- ~- ~--
-;:.>- • --- --_: ;;.-
PASS CAB LE TH ROUGH C LIP -

DRUM BRAKES ONLY
PARK BR AKE CAB LE
*N. D . SHOWN ON 3442742 FOR SECT I ONS A-A, B-B REFER SHT. '2
Figure 5-30
Park Brake Cable Routing
- CLIP
~
ml ,
';;~-
~.
~~yl
~K~, ,
,~
~~~~\. <,"" ~
~~~ / /~,
---
' ~~ )\' ~~\ ~\ 0 '
~ . \ \ ,',
', . \.
'~
B ,' ~
\I
>''~) l \ ~-.-:\:{;':';-:,:"-!KJ[
~
0~i,~,t; I l\~r - --- ~
'<
·"·)f);~; '
''. "' " ' ' ','\, •..
~ - ~~
~' ·~ ~- ' ~' ~,
/
TENSION D ISC
[6] - ' \ .. _' "". -~c
\ -/ j '. -.·-'- "-._ \, \

VIEW
XI
STOPLIGHTSW IT CH ---- - --._'-.,_
-<_:~
~
NUT ---------- I' .' '\. I I, )' , '- .: ""-'
,_ "': '
~ / \\....~ I\ '") 1//ji--

711.
: .,,, ~~- .1:
r d$ -!1 i ;' ~~
\:L_/ ~ - - - -- \ - -
~Jl
..II
.I _ «
~ \~ r n 1'\ I
------- RETURN SPR I NG
- BRACK~~p
STOPL SWITCH ~d
, -- ~~
~----- ------- PEDAL
/
~ M/ CYL_ PUSH ROD
ttl
:D
)>
"m
(/)
0
CJ1
I
Figure 5-31
w
Brake Pedal CJ1
r 0
CJ1
i I
w
0)
f
'~-==n:J
I'' aJ
0
JJ
--,1~1~lL_ -:--
)>
& ;'
~j'(~, "m
VAPOUR PIPE --
/
~~j CLIP }M (/)
~
FUEL PIPE
VAPOUR RETURN PIPE /

VIEW [6] SECTION A-A [ -)~~
:i>_::_'./');')
~--~!.cJ: \\
\ (./
~
I )
~ BR A K E H OSE ca( /( VIEW [ill

> /I 1
SEC T ION B-B
~\ - _r- - ~(
~-~~
) /
-/
~\
\' ~ ~
~\___- ~
c
~-- /
/~
/
_)
/
/_,
'- )
-r-/7
\' - () 0 ;
/
/
/
/ /
' / -~
/}
~-
f /
/'
""--
J
/ / / /
_, ,/ // / I () ()
/ -~~
) ,-, --
~
/
'../
/ ~
--
~- ~='~-- =" '?
~~
- ~:~//
_A~~A
/ Ci
- -:: FOR;ONTI NUATIONOF T YPE / '
ffi 20 - 25 Nm '/ -- REFER FI G. 5-2 3
() ~ - .::.:::.--
() A LL TAN GS TO BE BENT AROUND
PIPES ON I NSTALLATION
Figure 5-32
Rear Brake Lines
BRAKES 05-37
DIAGNOSIS CHECK SHEET
X Indicates Causes
XX I nd icates more possible Causes
CAUSE
Lea king Brake Line or Connection X X X

Leaki ng Wh ee l Cylinder or Piston Lin e X X X X X
L eak ing Ma ster Cylinder X XX X
Air In Brake Syste m XX X X
Contaminated or Improper Brak e Fluid X X X X
Leak in g V ac uum System XX X
Restricted Air Passage in Mast ervac X XX X
Damaged Mast ervac X X X X XX
Impro perly Assembled Mastervac Valving X X X X XX
Worn Out Brake Lining - Repl ace X X X X X X X X
Un even Brake Lin ing Wear - Replace or Correct X X X X X XX X
Glazed Brake Lining - Sand Ligh tly XX X X X X X
Incorrect Lining Materi al - R eplace X X X X X X
Contamin ated Brake Lining - Repl ace XX XX XX X X X X
Lin ings Damaged By Abu sive Use- Repl ace X XX X X X X X X
Excess ive Brake L ining Dust- Remove with Air X XX XX XX X XX X
Heat Spotted or Scored Brake Drums or Discs X X X X X XX X
Out-o f-Round or Vibrating Brake Drums X XX
Out -o f-Parall el Brake Di scs XX
Excessive Di sc Run -Out X
Faulty Automatic Adjusters X X X X
Incorrect Wheel Cylinder Sizes X X X X
Weak or Incorrect Brake Shoe Retention Springs X X XX X X XX X XX
Brake Assembl y Attachments- Mi ss in g or Loose X X X X X X X X
Insuffici ent Brake Shoe Guide Lubri ca nt X X X X XX XX
Restricted Brake Fluid Passage or Sticking Wh ee l
X X X X X X X
Cylinder Pi ston
Brak e Pedal Linkage Interference or Binding X X X XX
Imprope rly Adjusted Parking Brake X
Drums Tapered or Th rea ded XX
Incorrect Front End Alignm ent XX
Incorrect Tyr e Press ure X X
Incorrect Wh ee l Bearing Adjustment X X X
L oose Front Sus pension Attachments X X XX X
~--------~----------------------~-+--~~-+--~~-+--r-~-+~r-+--r--r --
Out-of- Balance Whee l Assembli es XX
Operator Riding Brake Pedal X X X X X I X _____
L..__ __ __ _ _ __ _ __ _ _ _ __!_____,L__L__!_____,L__L__!_____L__JL__l_____L__J_~---~.----~..
05-38 BRAKES
SPECIFICATIONS
DISC BRAKES - FRONT Brake Drum

Disc Inside Diam eter (Nominal) ... .. ....................... 160 mm
Type ............... ............. ................................................... Ventilated Maximum Out of Squ are ... .. ....... ............................ 05 mm
Diameter (Nominal) ...................................................... 268 mm (TIR with disc surface) .
Thickness ..................................................... 22.2 mm . Nominal Maximum Out of Round ................. ............... ... .. .. ...... 08 mm
Runout (Maximum) ............. ...... ....................................... .. 1 mm
Brake Li nings
(Rate of change .03 mm in 30 deg . rotation , maximum)
Type ...... ........ ......... . .... Res in bonded asbestos
Calipers
Width ....... .......... . ................... 25 mm
Make .................. ...... .......... .... .......... ................ ........ ... ........ Girlock
Thickness ................ .. ... ... ..... .... . ........................ 3.5 mm
Type .. ... .. ..... .... ................. ........ ... Single piston , slid ing ca liper
Bore Diam eter (Nominal) ... .. ............. ..... .... .. . ..... ... ... 54 .0 mm
ADJUSTMENTS
Disc Brake Pads
Disc Brakes - Front .......... No adjustm ent req uired .
Material .. ...... ... ........................ ........ ... Res in bond ed asbestos
Co ntact Area ......................... ..... ........... ... .... .. 156 em squ ared Drum Brakes- 8VK & 8VL. Self adjusting, park brake lever
on third notch from fully released posi ti on - adj ust relay rod
until wheel drags lightly. Wh eel should spin freely when
lever released.
REAR DRUM BRAKES (8VK & 8VL MODELS) Di sc Brakes - Rear 8VX & op tion JM8. No adj ustm ent
Type ............................... .. ....... Leading / Traling shoes req uired.
Foot Brake ........... ............... ........................ Hydrauli c Drum Park Brake - 8VX & option JM8. Park brake leve r on
Park Brake .... .................................... ....... ... ......... Cable & leve r third notc h from fully relea sed pos ition - ad ju st brake till
shoes co ntact drum firmly , then back off ad juster one
Brake Drum notch . and adj ust relay rod to remove slac k in cabl e. Wh eel
should spin freely when lever released.
Inside Diam eter (Nom inal ) ................. ..... .... .... .. ..... 228 .6 mm
Maximum Out of Round (New) .............. .... .. ... ...... ... .1 27 mm
Maximum Out of Round (Worn) ............................... 254 mm
MASTER CYLINDER
Brake Linings
Make .............. ........... ...... .. .. .. ........ .... ........ .............. . PBR
Type ...... ....... ...... .. ..................... Moulded asbestos - Riveted
Type ... .... .......... ....... ... ... ............... . ... ................. ..... .... Tand em
Width ........................................................ .. ...... ................. 50 mm
Bore Diameter (Nominal) 23 .8 1 mm
Contact Area ...... ..................................... ............... .. . 4 71 .6 mm
Maximum Stroke .... ......... .. ....... ............ ......... ........... .. 28 .5 mm
Wheel Cylinder Stampin g on End of Cy lind er ............... . .... 350
Bore Diameter ........ ... ........ .... ...................... ........ ...... ... 22.2 mm Fluid level ..... ... .. ............... 6 mm Below rim of rese rvoir
Minimum Displacement - Front ....... ......... ... .... 5.4 1 mm
Minimum Displacement - Rear ... ..................... ........ 5.74 mm
DISC BRAKES - REAR (8VX & OPTION JM8) Peda l Rati o ... .... .... ... ... .. .... ........ . ................... ...... ......... .. 4.9:1
Disc Line Pressure .. ... .. ...... .... ......... ... 5783 kPa at 44 5 N
Approved Hydra uli c Brake Fl uid ... GM 465 3M, Typ e 45 0
Type ............................ ............. ... ............................ .. .... .. ... ..... so lid
Diam eter (Nominal) ............. .. .. ..... ...... ........ ..... ........ . 274 mm
Thickness ................ ............ .......... ... ..... ........ 1 0.5 mm Nominal
Parallel and Run -out (Maximum) ..... .... .. .... .. ...... ..... .13 mm
BRAKE BOOSTER ASSEMBLY L6 , V8 & OPTION
(Rate of chan ge .03 in 30 deg. rotation , max.)
JM8
Caliper Make ...... ........... ...... ....... ....... . ........ .. PBR - Master-Vac
Make .. .. ........ .. ....... ........ ................... ... .. ....... ....... .............. . Gi rl ock Type .. ..... ... ......... ... Single - Vac uum Suspend ed - Tand em
Type ..... ... ..... .... ........ .. .... ... ....... .. Single pi ston ,sliding ca liper Va cuum Pi ston Diameter (Nominal ) ................. 230 mm
Bore Diameter (Nomina l) ........... ..... .. ....... . 38 mm Body Width (Nom inai )L6 ......................................... 1 09 mm
Body Width (Nominal ) V8 & OPTION JM8 .... 139 mm
Disc Brake Pads Boost Ratio L6 ..... .... ...... .. ............ .... ................... .. .. ....... 3: 1
Material ......... ... ... . ................. ............ . Resin bond ed asbestos Boost Ratio V8 & OPTION JM8 .. .......... ........... 3: 1
Co ntact Area ....... ........ ...................... ..... ..... 11 2.8 em squared Master Cylinde r Pu sh Rod Length ............... 0.58 - 0.84 mm
(from cy lind er mounting face)
Booster Pu sh Rod Length ...... ...... 19 1.5 or - 0.7 mm
DRUM PARK BRAKE - (8VX & OPTION JM8) (Centre Line of c levis hole to mountin g face o f booster) .
Type ... ...... Duo se rvo , cable and lever operated Min imum Stroke .......... .. ...... .......... .... .. ....................... 30.7 mm
BRAKES 05-39

Master Cy linder Rese rvo ir Attac hin g Nut .. ... 5- 5. 6 Nm Front caliper to knuckle bol ts .... ........................... 70 -85 Nm
Master Cy lin der Rese rvo ir Bolt ....................... .. 6.2- 6.8 Nm Front brake hose to caliper bolt ......................... . 27-34 Nm
Master Cylin der Plug ......... ...... 34-40 Nm Rear caliper to support bo lt .................................. 55- 70 Nm
Master Cylinder Attachin g Nuts ................. ...... 13- 14 Nm Rea r brake hose to caliper bolt ........................... 27 -34 Nm
Master Cylinde r to brac ket bolt ... ..... 40 -5 1 Nm Shi eld to caliper support bo lt ................. ............. 8-1 0.6 Nm
Master Cy lin der brac ket to panel nuts .. ...... 20 - 25 Nm Park brake lever assembly attac hing bolts ....... 20- 25 Nm
Booster to bracke t nuts ...... ... .. ...... ... . .. 15-2 0 Nm Park brake brac ket to caliper suppo rt bolt ...... 12- 16 Nm
Bracket to firewall nuts ......................................... 15 -20 Nm
05-40 BRAKES
NOT ES
ENGINES 06-01
SECTION 06
ENGINES
Subject Page
ENGINE ASSEMBLY L6 .................................................. 06-01
ENGINE ASSEMBLY V8 ................................................. 06-07
ENGINE TUNE AND EMISSION CONTROL ................ 06-11
FUEL SYSTEM .................................................................. 06-21
COOLING SYSTEM .......................................................... 06-27
SPECIAL TOOLS .............................................................. 06-29
TORQUE WRENCH SPECIFICATIONS ........................ 06-30
ENGINE ASSEMBLY
L6 ENGINES
INDEX
GENERAL DESCRIPTION ............................................... 06-01 ENGINE MOUNTINGS ...................................................... 06-04
ENGINE IDENTIFICATION .............................................. 06-02 CHECKING FRONT MOUNTINGS .......................... 06-04
MINOR SERVICE OPERATIONS ................................... 06-02 REPLACING FRONT MOUNTINGS ........................ 06-04
OIL PAN ...................................................................... 06-02 MAJOR SERVICE OPERATIONS .................................. 06-04
Removal .............................................................. 06-02 ENGINE ASSEMBLY ........................................................ 06-04
Installation .......................................................... 06-02 REMOVAL .................................................................. 06-04
REAR MAIN BEARING OIL SEAL ................................ 06-02 INSTALLATION .......................................................... 06-04
REPACKING REAR MAIN BEARING
UPPER OIL SEAL ..................................................... 06-02
REPLACING REAR MAIN BEARING OIL
SEAL ···················••H•••·················································· 06-03
GENERAL DESCRIPTION
Th e 2850 an d 3300 L6 engi nes are basically th e sam e as Th e 2850 engin e is standard equipm ent on, and only
th ose released for To rana UC and Hold en HZ Se ri es with avai lab le with , 8VK models. Th e 3300 eng in e is standa rd
min or modificati ons to suit th e VB Se ries environm ent. equipm ent on 8VL models and ava il abl e as a prod uc ti on
Th ese mod ifi ca ti ons in c lud e a revi sed oil pan , oil pi c k-up opti on on 8VK and 8VX models.
pip e and engin e mountin g brac kets. Th e engin e oil dipsti c k
has been reloca ted furth er forward.
06-02 ENGINES
ENGINE IDENTIFICATION VL . .... ... .... . .. .... 3300 High Compression

VM . ........... 3300 Low Comp ression
Th e engin e number stampings for the appropiate L6 en-
gin es are: Se rvi ce ope rati ons are simila r to tho se for L6 engines used
in previous series Holden vehicle s and are covered in
Engine No. Prefix App lica tion Holden HQ Se rvi ce Man ual - Volume 4 except as noted in
VD ......................... ..... 2850 Hi gh Compress ion th e foll owin g paragraphs.
OIL PAN 4. Ca refully place th e oil pan in position , install and

The revi sed oil pans have the oil sump area located forward ti ghten attaching sc rews and bo lts to 8- 11 Nm .
of th e front cross member to prov id e c lea ran ce for th e 5. Lower engin e and reins tall co mponents. Refill the oi l
stee rin g mec hani sm and c rossmembe r. The oil pan ca n be pan with th e specif ied quantity of SE quality eng in e oil
removed without rem ov in g th e engine from th e veh ic le. and th e coo lin g system with th e co rr ect amo unt of
coo lant and in hibitor.
Removal
1. Raise th e vehicle on a suitabl e hoist or suppo rt on REAR MAIN BEARING OIL SEAL
safety stands .
L6 engines for VB Series use a braded fabri c (rope type)
2. Disconnect th e battery gro und cab le.
rea r main bea ring oil sea l. Rope type sea ls have been used
3. Drain th e radiat or and oil pan . in Hold en eng in es for some time and th e op portunity has
4. Disco nn ec t th e radiator hoses and on Trimati c trans - been taken to re-print th e reco mm end ed repa ir and re-
mission models, disconnect th e oil coo ler hoses from placemen t procedu res for th e rope type sea l in thi s Manua l.
the conn ec ti ons at th e tran smi ss ion . Th e rope typ e rea r main bearing oil sea ls are pressed into
5. Support th e eng in e with a suitabl e liftin g hoo k such as grooves form ed in th e c rankcase and rear bearing ca p, to
Tool No. 6A37 and remove th e engin e mountin g to th e rea r of th e oi l co llectin g groove, to sea l aga in st lea ka ge
crossmembe r bracket bol ts. of oi l around th e c rankshaft. Th e upp er half of th e sea l can
6. Raise the front of th e engin e approximately 114 mm only be in stall ed into th e cra nkcase wh en th e c rankshaft is
(4-1 / 2 in) to allow removal of th e oil pan . removed; howeve r, it ca n be repacked whil e th e c ranksha ft
NOTE: An alte rnativ e meth od is to rai se th e engin e wi th a is installed.
lifting jack under th e oi l pan , pl ac in g a bl oc k o'f wood
between the oi l pan and jac k to prevent damag e to th e oi l REPACKING REAR MAIN BEARING UPPER OIL
pan . With th e engin e rai sed app rox im ately 114 mm (4- SEAL
1 /2 in ) place two suitable siz e bloc ks of wood between th e 1. Rem ove the oil pan (See oi l pan remova l)
eng in e and crossmember mounting brackets to sup port the 2. Remove th e rea r main bearin g ca p
engin e in the raised pos iti on, th en remove th e liftin g jack. 3. Use a brass too l mad e to d im ensions shown in th e
After raising the engine, remove th e oi l pan attach in g Spec ial Too l Group at th e rea r of thi s sec ti on to pack
screws, lower the front of th e oil pan and wi th d raw in a upper sea l as foll ows:
forward direction. a. In se rt packing tool aga in st one end of the seal in
th e cylind er bl oc k. Drive th e old sea l gently into
Installation th e groove until it is pac ked tightly. The ga p thu s
Installat ion procedures are the reverse to remova l, noting prod uced varies from 6.35 mm (0 .25 in ) to
th e foll owin g. 19.05 mm (0.75 in ) depending upon th e amount
1. Remove the old oil pan gaskets and end sea ls and of repac k req uired .
th oroughl y clean gasket surfaces of th e oil pan and b. Repeat step (a) on th e oth er end of th e sea l in th e
cylin de r block. cy lin der block.
2. Install th e oil pan sea l packings inside the rea r bearing c. Remove th e old sea l from th e bea rin g ca p.
cap outer groove aft er applying sealer to GM d. In stall a new rope type sea l half in th e ca p usin g
Spec ifi ca ti on HN1 373 (Si lastic Sealer 732 R.TV), to too l No. AU100 (Fig . 6- 1), to compress th e sea l
ca vity th en in stall th e oil pan side rail gaskets and firmly into th e groove. This sea l will ultim ately be
cement in pos iti on (Fig. 6-2) c ut to prov id e th e pac kin g pi eces for th e upper
3. In stall th e Neoprene rubb er end sea ls. seal.
e. Measure th e amount th e upper sea l was d riven up
CAUTION: Prior to installing th e Neoprene end seal to the one sid e in th e cy lind er block and add 1.59 mm
underside of th e timing gea r cover, ensure that th e seal (.062 in ) Usin g th e rea r main bearing cap as a
loca ting holes are th oroughly clean. Insert th e four loca ting holding fix ture and a si ngle edge razo r blade, cut
spikes through th e holes in th e timing gea r co ver, using a this length from th e newly form ed area of th e seal
poin ted nose pair of pliers, pull on th e spikes until th e sea l in th e ca p. Repeat th e proced ure for th e oth er
positively contacts its mating surface on th e timing cover. side.
ENGINES 06-03
f. Work th ese pi eces into eac h of th e gaps which

have been made at th e end of th e sea l in the
cy lind er bloc k until flu sh with the parting lin e. It
may be necessary to trim th e end of th e seal to
-
ensure th e sea l end s are flu sh with th e bl oc k and
no fibre end s are protrudin g ove r th e metal ad-
jacent to th e groove. TOOL
No. 6A60
g. Form anoth er new sea l in th e beari ng ca p using <!!"' . or
tool No. AU 1 00 (refer Fig. 6-1) to co mpress th e ;;
AU 100
seal firml y into th e groove, use a rol ling moti on to ;..--
in stal l th e sea l to achieve uniform sea l co m-
pression.
h. Trim sea l ends fl ush with th e ca p.
i. Cemen t rope sea l to groove with neo prene ce ment
HN1 068 part numb er 7425229 as shown in
Fig. 6-2 .
4. Apply SILASTIC SEA LER HN1 373 - Part Numb er
M3798 1 to cut fa ces of sea l and joint faces of cylinder
block as shown in Fig. 6-2.
5. Install the rea r mai n bea ring cap and ti ght en attac hing
bolts to 8 1-95 Nm .
6. In stall oi l pan (see oil pan instal lation.)
REPLACING REAR MAIN BEARING OIL SEAL Figure 6-1
Rep laci ng th e compl ete upper half of th e rea r main bea ring Forming New Seal in Cap
oi l sea l will require th e c rankshaft to be removed from the
cy lin der block.
1. Remove th e engine asse mbly as outlin ed in thi s sec- seal to achieve uniform seal co mpression.
tion.
2. Remove the c ranksha ft as outli ned in HQ Se ri es 5. Trim th e sea l end s flu sh with th e block. Ensure th at no
Holden Serv ice Manual Volume 4 - L6 Engines Sec- fibre end s are protruding over th e metal ad jacen t to th e
ti on . groove.
3. Remove the upp er half of th e rear main bearing oi l sea l 6. Form a new sea l in the bearing cap as outlin ed in (g)
from th e groove in th e cylin der bloc k. 'Repac kin g Rea r Main Bearing Upper Oil Sea l. '
4. Clea n th e seal groove and in stall a new half seal in the 7. Re in stal l cra nkshaft , payin g particula r attenti on to th e
groove using Tool No. AU1 00 to co mpress the sea l sea lin g of th e rear main bearing ca p. Refer Fi g. 6-2.
firmly in the groove, use a rolling motion to in stall the 8. Rein stall engin e.
IN SI DE DIAMETER OF
SEA L INSTALLED
65 .66/ 64.69 mm
APP L Y THIN COAT OF
0 (2 585 / 2 .547 in.)
HN1373, TYP E 1 SEALER
TO CUT FACE OF ROPE
SEA L AS SHOWN
APPLY 1.0 16/ 1.524 mm

(.040/.060 in. BEND
OF HN1373 SEALER
AS SHOWN AT JO INT
FACE ON CYL. & CASE
- CUT FLUSH TO .25 4mm

rB-=.--. (.0 10 in.) ABOVE JOINT
FACE
~ CA P-REAR MAIN BEAR IN G

~:--"----I'"-CE MENT ROPE SEAL TO
GROOVE WITH NEOPR ENE
CEMENT HN1068 AS SHOWN
(BOTH CYL. CASE & CAP)
Figure 6-2
Rear Main Bearing Oil Seal Installation Details
06-04 ENGINES
ENGINE MOUNTINGS REPLACING FRONT MOUNTINGS

L6 engi ne mountings are basically the same as on Holden With th e engine raised slig htl y, remove the nut, sp ring
washer and flat washer from th e th rough bolt attac hing th e
HZ Se ri es; however, there are some detail c hanges to the
bracket and spacer locations. Refer Fig . 6-3 and 6-3A for mountin g to the c rossmember bracket and wi thdraw the
assembly details of front and rear engine mountings . bo lt. Remove the engine bracket to mounting nuts, lock
was hers and flat washers and bo lts th en remove th e
CHECKING FRONT MOUNTINGS mount ing.
For identification of parts refer Fig. 6-3. Raise th e engi ne In stall th e new mountin g, lower th e engine and ti ghten al l
mountin g bolts to specification Refer Fig . 6-3 for ti gh-
to remo ve the weight from th e moun tings and to place a
tening torques .
slight tensi on on rubbe r. Observe both mountings while
raising the engine to ensure that th e mountin gs have not
separated from th e metal plate and that th e rubber has not
deteriorated or split through the centre.

tension . On Trimatic transmission models, remove th e
ENGINE ASSEMBLY detent so len oid and TCS switch ca bl es and remove
coole r hoses , pl ug openings .
REMOVA L 12. Rem ove the propel ler shaft and in se rt a p rotector in the
1. Drain th e cooling system and oil pan . end of the transmission rear extension to prevent loss
of oi l.
2. Disconnect battery cables at battery and remove air
cleaner. 13. Di sco nn ec t th e clutch con trol
3. Remove engine hood. 14 . Install Tool No. 6A37 engi ne liftin g hook and remove
th e front engine moun ting to c rossmembe r bracket
4. Remove radiator and disconnect heater hoses.
through bolts and th e rear transmission mounting to
5. Disconnect battery cable and solenoid switch wire crossmembe r attaching bol ts, remove crossmembe r.
from starter motor, wires from ge nerat or , igni tion co il
15. Rai se the engine with the fron t tilt ed upwards and lift
primary + terminal and the temperatu re and oil
th e engine and transmission out of the vehic le.
pressure switches .
6. Disconn ect the fuel tank to pump line at fuel pump and CAUTION: On air co nditioned vehicles, do not permit the
disconnect EEC hoses at ca rburettor. Rem ove engine to swing forward and damage refrigerant pipes or
necessary hoses from vacuum so urce connec tor. condenser.
7. Remove the exhaust pipe to manifold nuts.
8. Di sconnect th e throttl e and c hoke co ntrol cab les from INSTALLATION
the carburettor . Reverse to removal operat io ns with att en tion to th e fol-
9. On models fitted with air co nditi oning , th e co mpressor lowing :
can be remo ved and support ed out of th e way without 1. Coat threads of exhaust pip e to manifold attaching
disconnecting the hoses. stud s with anti-seize compo un d to G MH speci fi ca tion
1 0. Raise th e vehicle and place on jack stan ds . HN1 325.
11 . Di sconn ect th e gear shift controls from the tran s- 2. Make sure the oil pan is fi lled with the specified
mi ss ion . Refer Clutch and Transmission Sectio n of this quantity of SE quality engine oil , and the cooling
Manual for detail s. Di sconnect back-up swi tc h cab les system is fil led wi th th e co rrect amo unt of coolant and
(wh ere applicabl e). Withdraw the speedometer cable inhibitor.
fitt ing and dri ven gear from th e tran smission rear ex- 3. Check and adj ust ignition tim ing .
ENGINES 06-05
FLANGE POSITION
MAY BE ASSEMBLED FR0' 1
OU T BOARD
EITHER DIRECTION
R. HAND SIDE ,,
34 - 46 Nm
* FOR C60 DETAILS REFER FIG . 2- 47 in A / C SECTION
Figure 6-3
Front Engine Mounting Installation Details - LG Engines.
06-06 ENGINES
SPA CER THM 400 TRANSM ISS ION ONLY

12 PLACES)
REAR ENG INE MOUNT ASM.
I
~ REAR CROSS MEMBER ASM .
WASHER
I2P LA CE~- ; G 1~S PA CER
Gil)
FOLD DOWN~~
~
COFlNtl'l Af- TER (
t'i .fl
tG> ~
WA SH ER
12 PL ACES)
A SS L MBLY - ~ WA SHER BOLT @, 4 0 -50 Nm
/[)BO LT_ / 12 PLACES ) 12 PLACES) 34 -46 Nm

12 PLACI::S)
/)\ 40 -5 1 N111
Figure 6-3A
Engine Rear Mounting - All VB Models.
ENGINES 06-07
ENGINE ASSEMBLY
VB ENGINES
INDEX
Subject Page Subject Pag e

GENERAL DESCRIPTION ............................................... 06-07 ENGINE MOUNTINGS ...................................................... 06-09
ENGINE IDENTIFICATION .............................................. 06-08 CHECKING FRONT MOUNTINGS .......................... 06-09
MINOR SERVICE OPERATIONS ................................... 06-08 REPLACING FRONT MOUNTINGS ........................ 06-09
OIL PAN ............................................................................. 06-08 MAJOR SERVICE OPERATIONS .................................. 06-09
REAR MAIN BEARING OIL SEAL ................................ 06-08 ENGINE ASSEMBLY ........................................................ 06-09
STARTER MOTOR ........................................................... 06-08 REMOVAL .................................................................. 06-09
INSTALLATION .......................................................... 06-09 CYLINDER HEAD REMOVAL & INSTALLATION ...... 06-10
GENERAL DESCRIPTION
Th e 4.2 and 5.0 litre hi gh co mpress ion V8 engin es are Th e 4.2 litre engine is standard equ ipm ent on 8VX Mode ls
basically ca rried ove r from Holden HZ Series with and avai lable as an opti on on 8VK and 8VL Models. The
modifi ca ti ons to th e oi l pan, engin e oil dipstick loca ti on, 5.0 litre engine is availab le on all Mode ls as a production
starter motor locati on, engine mounts and exhau st opti on only.
manifolds to suit the VB Se ri es design .
06-08 ENGINES
ENGINE IDENTIFICATION VT ............................................... . ............. 5.0

Se rvice operations are similar to th ose for th e 4.2 and
The engine number stampings for th e approp riate VS en-
5.0 litre engin es used in prev ious series Holden veh icles
gines are :
and are cove red in Holden HQ Se rvi ce Manual - Volume
Engine No . Prefix Applica ti on 4 except as noted in th e following paragraphs .
VR ......................................................... .... . ..... 4.2

OIL PAN
Th e oil pan has been revised in that the oi l sump area has to remove the oi l pan with the engi ne in place, it will be
been relocated to be forward of the front c rossmember to necessary to remove the eng in e to repack the rear main
provide clearance for th e steering mec hani sm and cross- bearing oil seal and then proceed with the operations
member. Due to th e location of the engine, it is not rec- outlined under the heading 'Repacking Rear Main Bearing
ommend ed th at th e oi l pan be removed with th e engin e in Upper Oil Sea l' in the L6 engine section of thi s Manual.
th e vehicle.
STARTER MOTOR
REAR MAIN BEARING OIL SEAL
The sta rt er motor on VS eng in es has been relocated to
VS eng in es for VB Se ri es use a braded fabri c (ro pe type) clea r the rack and pinion stee rin g gear. This has been
rea r mai n bea rin g oil sef} l. Th e upper half of th e seal ca n ac hi eved by th e use of a new starter drive housing whic h
ei th er be replaced or repac ked . For details of th e pro- pos iti ons th e starter lowe r on th e engin e and rotates the
cedure involved , refer to 'Rea r Main Bea rin g Oil Sea l' in th e so lenoid to a lower pos ition Th e fly wh ee l lower cover has
L6 engine secti on of thi s Manual. Beca use it is not po'ss ibl e been modified to accommodate thi s c hange.
& (2 PLACESI
FRONT OF CAR
ENG IN E FR ONT
MOUNT ING BRACKET
SUPPORT ASSEMBLY
& BOLT
& BOLT
£ 40 ° 48 Nm
~ 52 ° 72 Nm
£ 34 ° 40 Nm
LEFT HAND SHOWN
& 24 °32 Nm
Figure 6-4
Front Engine Mounting Installation Details - V8 Engines
ENGINES 06-09
REMOVAL CHECKING FRONT MOUNTINGS

1. Disconnect battery leads . For iden tifi cation of parts refer Fig . 6-4. Rai se th e eng in e
2. Raise ca r and pl ace ca r on jack stand s. to remove th e weight fro m th e mountings and to place a
3. Disconnect battery and so lenoid wires from starter sli ght ten sion on rubber. Observe both mountin gs whil e
termin als. rai sin g the engine to ensure that th e mountings have not
separated from th e metal plate and that the rubb er has not
4. Remove Left Hand ex haust fl ange attach in g nuts.
deteri orat ed or split through th e cen tre.
5. Remove Left Hand engin e mountin g through bolt and
raise engi ne 40 - 50 mm . REPLACING FRONT MOUNTINGS
6. Remove start er attaching bolts and slid e start er fo r- 1. Place a bl oc k of wood between th e engine oil pan and
ward over front suspension c rossmember until it can a jac k to prevent th e oi l pan being damaged. Raise th e
be removed from under fron t of ca r. engine slig htl y.
2. Remove mounting to c rossmember bracket through
INSTALLATION bolt, nut and spring was her, then withdraw through
Installation procedures are reverse to removal. bolt.
3. Remove eng in e bra c ket to mounting nuts, spring
ENGINE MOUNTINGS washers, bolts and mo unti ng .
In stallati on is reve rse to remova l operation s. Tighten all
V8 engine mountings are basically th e sa me as on HZ
bo lts to speci fi ca ti ons. Refer Fig . 6-4 for ti ghten in g tor-
Se ri es; however, th ere have been so me detail changes to
ques.
th e brackets and spacer locati ons. Refer Fig . 6-3A and 6- 4
for assemb ly details of front and rea r engin e mountings.
ENGINE ASSEMBLY tran smissio n rear extension. Disconnect back-up lamp

ca bles (where appli cable). On Automatic Transmission
REMOVA L Models , remove the deten t so lenoid and TCS swi tch
1. Disconnect battery cab les at battery. cables and rem ove th e coo ler hoses, plug openings.
2. Drain coo lin g system and oi l pan. 16 . Attach a suitab le engin e lifting hoo k and raise engi ne
sli ghtly to take weight off mounts.
3. Remove air clea ner.
17. Remove th e fron t engi ne mountings to crossmembe r
4. Remove eng in e hood.
bracket through bolts, nu ts and spring washers and
5. Remove radiat or. wi thdraw the through bolts.
6. Loosen the generator and remove fan belt, th en re- 18 . Remove th e rea r tran smiss ion mounting to cross-
move the four retaining bolts from th e fan assembly member bolts, and sp rin g washers, remove cross-
and remove fan and assoc iated parts. member.
7. On models fitted with air condi ti on in g, th e comp ressor 19. Raise engine with front tilted upwards and lift the
can be removed and supported out of th e way wit hout engin e and transmission out of the vehic le.
disconnecting the hoses.
8. Disconnect wires at starter so lenoid, generator, tem- CAUTION: On air conditioned vehicles, do not permit th e
perature switch, oil pressure switch and co il. engin e to swing forward and damage refrigerant pipes or
9. Disconnect the throttle control cable from th e carb u- co ndenser.
rettor.
1 0. Disconnect the fuel pump to tank lin e at th e fuel pump
and disconnect EEC hoses at carb urettor. Remove INSTALLATION
necessary hoses from vacuum sou rce con nector. Reverse to removal operations with attention to the fol-
11 . Raise the vehic le and place it on jack stan ds. lowing:
12. Remove exhaust pipes at manifold flanges . 1. Coat th reads of ex haust pipe to manifold at tachi ng
13. Remove the propeller shaft and insert a suitab le plug stu ds with anti-seize co mpound to GMH specificati on
in th e end of th e transmission. HN1325.
14. Disconnect th e gear shift cont rols from the trans- 2. Make sure th e engin e is filled with th e specified
mission. Re fer Clutch and Transmissions Secti on of quantity of SE quality eng in e oil and the coo ling system
thi s Man ual for detail s. is fille d with th e co rr ec t amoun t of coolant and in -
15. Remove the fittin g holding th e speedometer cab le and hibitor.
withdraw the cab le, fittin g and driven gea r from th e 3. Chec k and adjust ign iti on timing.
06-10 ENGINES
CYLINDER HEAD REMOVAL AND the engine centreline do not have sealer app li ed to th e
threads. Two of these bolts are identified as numbers 3 and
INSTALLATION 5 in Fig . 6-5. No sea ler shou ld be app li ed to th e co m-
Procedures for removing th e cy lind er heads on VB Series parable bolts on the other head.
with V8 engines are essenti ally th e same as for previous
models and covered in the HO Service Manual, Volume 4. B. Tighten the cylin der head bolts in two stages to 54 -
Wh en in stalling th e cyl in der heads the following ti ghten in g 68 Nm and 88 - 1 02 Nm.
proced ure must be observed when installing the cylin der
head bolts. NOTE: The two (2) bolts on each cylind er head c lo sest to
the engine cent reline must not be tightened beyond 54 Nm .
A. Coat the threads of twenty (20) cylinder head bolts Two of these bolts are identified as numbers 3 and 5 in
with sea lin g compo un d, part number 3835215. Fig . 6-5. The 54 Nm torque applies to the comparab le
NOTE: The two (2), bolts on each cylind er head closest to bolts on the other head.
Figure 6-5
Cylinder Head Tightening Sequence
ENGINES 06-11
ENGINE TUNE AND EMISSION CONTROL

INDEX
ENGINE TUNE ................................................................... 06-11 OPERATION ............................................................... 06-1 3
GENERAL DESCRIPTION ............................................... 06-11 THERMAL VACUUM SWITCH-SERVICE
CONDENSED ENGINE TUNE SPECIFICATIONS ....... 06-11 OPERATIONS ............................................................ 06-14
EMISSION CONTROL ...................................................... 06-13 On Vehicle Check ............................................. 06-14
GENERAL DESCRIPTION ............................................... 06-13 Off Vehicle Check ............................................. 06-14
V AC SYSTEM-3300 HC WITH AUTOMATIC Replacement ...................................................... 06-14
TRANSMISSIONS ............................................................. 06-13
ENGINE TUNE
GENERAL DESCRIPTION
En gin e tun e proce dures outlin ed in th e Holden HO Se rvice li sted below and di stributor ad vance detail s are given in
Manual, Volum e 4, carry over in general for VB Se ri es Fi g. 6-6 .
vehi cles . Co nd ensed engin e tun e spec ifi ca ti ons for VB are
I
IDLE SPEED R.P.M. DISTRIBUTOR SPARK PLUG
FAST ADVANCE POINTS

ENGINE PROD. DWELL
TRANS. NORMAL (2ND BTDC @ GAP GAP TYPE
SI ZE OPTION ANGLE
STEP) R.P.M. (APPROX.)
3° BELOW
2850 HC L01 MAN . 850N * R43T
900
AUTO . 6500 * 6° BELOW

3300 L C L23 30/ 35 0. 5m m 1. mm 45T
MAN . 850N * 900
AUTO. 6500 * 6 ° BELOW

3300 HC L14
MAN . 850N * 900
AUTO . 6250 * 44T

4.2 L36 0.4mm 1. mm
MAN. 900N *
1350 :!: 120 :!: ,o
r---- · 50N AT 1350 26/ 30
AUTO. 6250 *
5.0 L31
MAN . 850N *
run -in ve hi cles , unl ess th ey are subj ec t to comp laints of

CONDENSED ENGINE TUNE
stalli ng or runnin g too fast.
SPECIFICATIONS
Should idle speed adju stm ent be 'eq uired, follow th e
NOTE: As ca rburettors are preset to atta in the spec ifi ed proced ures fo r th e appropriate carburettor outlin ed in th e
idl e speeds wh en run - in (at least 3000km), it is not required 'Ca rbu re ttors Se rvi ce Manual Suppl ement ' pa rt number
to adju st th e idl e speed setti ngs on new vehicles and most M3793 1.
06-12 ENGINES
DIST. IDENTIFICATION ON
CENTRIFUGAL ADV A NCE VACUU M ADVANCE
PART ENGINE LABEL ON VACUUM
ENG . DEGREES AT ENG. R.P.M. ENG . D EGREES AT INS. Hg (kPa)
NUMBE R ADVA NC E UNIT
START INTER M EDI AT E FU L L START FULL
Between 3 .5 & 6 .5 11/ 15 @ 11

993899 2 2850 1.7 /5 .7 @ 1400 17 / 21 @ 2000 26/ 30 @ 4400 3° Blue
(12 & 22) (3 7)
Between 4.5 & 7.5 14/ 18 @ 12

9946937 4 .2 0/2 @ 750 16/ 20 @ 2500 27 / 31 @ 4400 12° Red
(15 & 25) (40)
Betwee n 6 & 9 14/ 18 @ 14

9946938 5 .0 0/2@ 750 16/ 20 @ 2500 22/ 26 @ 4400 12° Blue
(20 & 30 ) (47)
33 00 HC Betwee n 3.5 & 6.5 11 / 15 @ 11

9946005 0/2@ 1000 14/ 18 @ 2000 23 / 27 @ 4400 6° Yellow
AU TO . (12 & 22) (37)
3300 HC - 1 T o 2.2 @ 4 .5 11 / 15 @ 11
9200461 0 0/ 4 @ 1000 14/ 18 @ 2000 23 / 27 @ 4400 6° Red
MA N. (15 ) (3 7)
3300 LC Between 3 .5 & 6.5 11 / 15 @ 11

9946315 0/ 2 @ 1100 22/ 26 @ 2000 33 / 37 @ 4400 6° Gree n
A LL (12& 22) (37)
Figure 6-6
Distributor Advance Details
ENGINES 06-13
EMISSION CONTROL
GENERAL DESCRIPTION
Emiss ion co ntrol devices for L6 and V8 engines ca rry ove r ator in th e EEC System has bee n replaced by a revi sed fu el
from co mparab le HZ Se ri es engines with the foll owin g tank venting arrangement. Refer Fuel Tank and Exha ust
excep ti ons . The vac uum advance co ntrol system on 3300 System in thi s Manual for detail s. Th e emi ss ion control
high compression engines with automati c tran smi ss ion has device application chart in thi s secti on gives detai ls of th e
been revised and on all models, the liquid / vapo ur separ- appli ca tion of th e various emi ss ion co ntrol features .
ENGINE SIZ E AND TYPE 2 .B50L6 3300 L6 4.2 VB 5 .0 VB
TRANSMISSION MAN MAN AU T O MAN AUTO M AN AUTO
EVAPORAT I VE EMISSION CONTROL SYSTE M X X X X X X X

With Canister and Filter X X X X X X X
POSITIVE CRANKCASE VENTILATION SYSTEM X X X X X X X

With Valve X X X X X X X
With Filter X X X X X X X
CONTROLLED CO MB USTIO N SYSTEMS CO MPONENTS X X X X X X X

Carburettor Modifications X X X X X X X
Exha ust Gas Heat System X X X X X X X
Special Distributor Curve X X X X X X X
Special Camshaft X
IDLE STOP SOLE NOID X X X X X X X

Throttle Shut Off Type X X X X X X X
AIR PRE HEAT SYSTEM X X X X X X X
VACUUM ADVANCE CONTROL SYSTEM X X X X X X X

Th ermal Vacuum Switch X X X X X X X
V acuum Delay Valve X X
Cold Feed Switch X X X X X X
Transmi ssion Control Switch X X X X X X
Solenoid X X X X X X
EXHAUST GAS RECIRCULATION SYSTEM X X X X

Thermal Vacuum Switch X X
Emission Control Devi ce Applicatio n Chart
VAC SYSTEM - 3300 HC WITH AUTOMATIC a port si tuated above th e throttl e valve so that vacuum is
TRANSMISSION not available at id le or full throttl e. In ord er to prevent th e
eng in e ove rheating in high ambient temperatures, th e
The vac uum adva nce co ntrol system for 3300 HC engines thermal vacuum switch (TVS) is used to provide vacuum
with automatic transmission has been revised in that the directly from th e intake manifold to advance the igniti on at
TCS So lenoid, co ld feed swi tch and th e Transmi ss ion idle und er high temperature cond iti ons.
Con trol Switch have been deleted. Th e Co mponents of th e
system are therefore, the th erma l vacuum switc h and
co nn ec tin g hoses. With th e vehicle ope ratin g in any gea r and th e coo lant
tempera ture below 1 04 degrees C, th e 'ported ' vacu um
OPERATION signa l is directed via th e th ermal vacuum switch to th e
Und er normal co nditi ons, the eng in e spa rk is advanced by distri butor to advance th e spark . The manifold port at th e
mea ns of a 'ported' vacuum signa l. Vac uum is taken from TVS is blocked by the pi ston. Refer Figs. 6-7 and 6-8.
06-14 ENGINES
TO MA NI FO LD - - -- - - - - - -- - ,
VACUUM
TH ER MA L V AC UUM SWITCH
CAR BUR ETTOR
D ISTR IB UTOR
Figure 6-7
Vacuum Advance Control System - 3300 HC-Automatic
Shoul d th e coo lant temperature reac h 1 04 degrees C at Off Vehicle Check

idl e, th e pis ton in th e th erm al vacuum switc h moves to 1. Remove switch and connec t tes t hoses to distri buto r,
cover th e port to the ca rb urettor thus bloc kin g th e vac uum ca rburettor and manifold ports. Ca rry out step 3,
signai.( Fig. 6-9). Th e manifold port and d istri butor port are above.
now co nn ec ted prov id in g full vac uum advance and thu s
2. Imm erse threaded end of switch and a th ermometer in
preventing engin e overheat in g. A summ ary of the VAC
system is shown in Fi g. 6- 1 0. a co ntainer of triethylene glycol. (Do not use a norm al
ant i-fr eeze suc h as ethylene glyco l) .
3. With container on hot plate, gradually raise tempera-
ture of trieth yl ene glyco l, whil e ag itatin g sli ghtl y, to
approxim ately 88 deg rees C and ca rry out step 5 of
'o n vehicle' c hec k.
THERMAL VACUUM SWITCH - SERVICE
OPERATIONS Replacement
1. Di sco nn ec t hoses from switch.
On Vehicle Check: NOTE: If engine is hot, release press ure in rad iator by
1. With engi ne cold, in stall a temperatu re ga uge to th e removing ca p.
engine. 2. Remove swi tc h, (g rip lower metal section).
2. Remove and pl ug manifold hose at th erm al vac uu m 3. Install repl ace ment switc h app lyi ng sealer part
swi tch, d isco nn ect hose from swi tch to d istributor at number 38352 14 to thread and ali gn ports by turn ing
th e d istrib utor and disco nnect and pl ug ca rburettor upper plasti c body as shown in Fi g. 6-1 1.
hose at TVS. 4. Reco nn ect hoses. Top up radi ator and refit cap.
3. Blow through th e di stri butor port on TVS (not hi gh
press ure air) and c hec k that air ex its from th e ca r-
burettor port.
4. Blank off rad iator, start engin e and warm to approx-
im ately 88 deg rees C. Repeat step 3 every
3 degrees C ri se in temp eratu re ove r 88 deg rees C.
5. At betwee n 99-1 04 deg rees C, th e swi tc h shoul d
operate allowing air to exit from the man ifold port only.
ENGINES 06-15
TO
DISTR IBUTOR

TVS Operation - Water Temperature BELOW 104 degrees C. - TV S Operation - Water Temperature ABOVE 104 degrees C -
3300 HC-Automatic 3300 He-Automatic
NO
IS
COOLANT
TEMPERATURE 1 - - - - - 1
ABOVE
104°C YES
Figure 6-10
V AC System Summary - 3300 HC - Automatic
i-l
n~
__I I
I·-~~
I \J I
~TVSTO
~ _j _j
CARBURETTOR
TVSTO~
D ISTR IBUTOR
MANIFOLD
TO TVS
- - -- TO MANIFOLD
----------- . - TOCARBURE TTOR
U..r' - - - - - - - - -- - TO D ISTRIBUTOR
Figure 6-11
V AC System Hose Routing - 3300 HC - Automatic
\ 0
en
I
..I.
en
[lli
m
I r z
CARBURETTOR -~
HOSE - CANISTER TO FUEL BOWL VENT
G)
....r- STRAP
I z
m
n /1
;-lj
en
,',
\ ~ '
<;,~---\\;_
HOSE - CA RB . TO T .V.S
HOSE - M ANIFOLD TO.

T .V .S
- HOSE - CA NISTER T O \\
CARB. PURGE
~v
: t~ __,_
' ~ L.. _ t?}__
---<._ --
&!; ' l
' --=
ROCKE
R COVER \
~
\
.. _, ST~
RAPJ
HOSE _ CA R B. TO E.G. R . ~
-~ ~'-I!J ~:- ~.__-.-
(L\::=:::/', -
VIEW 0
'- FUEL PIPE

VIEW
ITJ
SECTION A
Figure 6-11 A
Emission Control System Hose Routing - 3300 HC With Automatic Transmission
ffi] (;
1r
SOLENOID
1 CARBURETTOR
HOSE - CANISTER TO
FUEL BOWL
I VENT
....__l.__
HOSE - MAN I FOLD

y STRAP HOSE - T .V .S. TO SOLENOID TO T .V .S.
t?
- HOSE - CANISTER T O
CA RB . PURG E
STRAP ---, HOSE - CARB . TOJ

SOLENO I D
ROCKER COVER VIEW 0
H OS E - CARB . TO E.G.R .
EX C. 2850 MANUAL TRANS .
m
VIEW [}] z
G)
SECTION A FUEL PIPE -z
m
(/)
0
0)
Figure 6-11B .....
I
Emission Control System Hose Routing - L6 Except 3300 HC With Automatic Transmission
""""
0
mI
....L
ClO
HOSE - CANISTER T O
TO E.G.R. THERMAL m
CARB . PUR GE VACUUM SWITCH z
G)
-z
HOSE - MAN IF O L D
TO T .V .S.
TO CAN IST ER
HOSE - T.V. S. TO
7 TO
SOLENOID
m
(J)
SOLENO I D
d :--(
~ /~~
, -· ~ /~
\\/ TO
~
/~-----::.:
SOLENO I D
HOSE -
T V S T O CA R B _ /
DELAY~
WITH M40
HOSE - T .V.S TO
E.G.R. VALV E WITH M40 SPARK
VA L VE "'
~~
~
///
1
PL AST IC BODY ROTA TED TO T HI S
TO D I STRIBUTOR ~
V I EW []]
/ POS ITI ON INDEPENDENTLY O F
<"
_:::<~ SW ITCH MAIN BODY POS ITI ON
' "'- '
V IE W IT]
"""
"'(
~~ ROCKER COVER
.·. ~ ENG I NE H ARNESS
~
SEC TIO N A- A
Figure 6-11C
Emission Control System Hose Routing - 4.2 VS Engine
HOSE - DISTRIBUTOR ---.,
TO SOLENOID ~ ROC K ER COVER
WITH M4 1' - SECT I ON A
PLASTIC BODY ROTA TED THIS

POSITION INDEPENDENTL Y OF
SW ITCH MAIN BODY POSITI ON
VI EW 0
//
~ /
"" CA P - CARB.
VACU UM PORT
~-
m
z
G')
-z
m
CJ)
0
en
I
Figure 6-110 ....L
Emission Control System Hose Routing - 5.0 VS Engine CD
06-20 ENGINES
NOTES
ENGINES 06-21
FUEL SYSTEM
INDEX
GENERAL DESCRIPTION ............................................... 06-21 THROTTLE CONTROL .................................................... 06-21
SERVICE OPERATIONS ................................................. 06-21 REMOVAL .................................................................. 06-21
INSTALLATION .......................................................... 06-21
ADJUSTMENT ............................................................ 06-21
ACCELERATOR CONTROL LEVER ............................. 06-21
GENERAL DESCRIPTION
The fu el systems for VB Se ri es engin es are carri ed ove r li on for th e carb urettors - Be ndi x Stromb erg Se ri es 'BX'
fro m co mparab le Hold en HZ Se ri es engi nes. Se rvice used on L6 engines, the Bendix Stromberg 'WW ' for
Procedu res for air c lea ner elements and fu el pumps are 4.2 litre engin es and the Roc hester Quadraj et for 5.0 litre
cove red in th e appropria te fu el sys tem sec ti ons of th e engi nes - are cove red in th e 'Ca rburettors Se rvice Manual
Holden HQ Serv ice Manu al - Vo lum e 4. Se rvice lnfo rma - Suppl emen t', Part Number M3793 1.
SERVICE OPERATIONS
THROTTLE CONTROL co rr ect location of c lips gromm ets, etc. Adjust throttl e
cabl e aft er in sta llati on.
A cabl e operated throttl e co ntrol is fitt ed to all engin es. Th e
cable is in sul ated at all mountin g points to prov id e noise
in sul ati on. ADJUSTMENT
1. With acc elerator pedal pu shed all th e way to the floor,
REMOVAL ad ju st nuts on th e outer ca bl e at support bracket to
1. Unclip in ner cab le from ball stud on carburetto r thro tt le fu ll y open throttl e valve.
lever. 2. All ow accel erat or peda l to assume free posi ti on and
2. Loosen lock nu ts and remove outer cab le from ca bl e adju st sc rew on throttle pedal so tha t pedal has no free
support bracket, attac hed to ca rburettor on L6 or in- play and th e cab le is loaded. (Refer Fig. 6- 14). (Ove r
take manifold on V8. (Refer Fig. 6- 12 or 6- 13). tensionin g wi ll aff ect engine id le speed).
3. Di sconn ect the id le stop so lenoid and c hec k to ensure
3. From inside the vehicle, unclip th e inne r cab le retai ner
th at th e slow id le speed is not above 550 RPM (a ll
from th e thrott le lever. (Refer Fig. 6-14)
engin es with transm ission in neutral).
4. With draw the cab le assembly thro ugh the firewa ll
4. Reco nnect Id le Stop So lenoid.
towards the front of the car.
ACCELERATOR CONTROL LEVER

The accelerator co ntrol leve r support brac ket is cove red by
a plas tic so un d deadener ca p. Th e co ntrol lever is sup-
INSTALLATION po rt ed on two bushes mounted in thi s cap, and they are
In stall ati on is the reverse to remova l operations wi th at- re tain ed by c lips on eac h end of th e contro l leve r pivot
tent ion to the following: Ens ure th at th ere are no kin ks or (F ig. 6- 15).
bends in th e cab le, rep lace cab le if th ese are ev ident. The The accelerator peda l is re tain ed on the con trol lever as-
th ro ttl e ou ter cab le is lined with a resi n ma teria l and does sembl y by a pin and sprin g. Refer Fig. 6- 15 fo r assembly
NOT req uire lu brica ti on. Re fer To Figs. 6- 12 and 6-13 fo r detail s of peda l and co ntro l.
0
en
I
1\)
1\)
m
z
THROTTLE LEVER
"m-z
' ft~
i·;
'
/
~
~
~
--~-- -
~~-~~
-~ ~
____-
-
GROMME T - S UPPOR T PL ATE
~
;:3,
-=-=---~
~
y/'
t,
\
(J)
~~~· ~
# .-
~: u ~.,~ ·
~l_____
="II
~ r""-
----- ------------------ 1 ~~ -
-.:-- LUBRICATE
PIVOT POINT
~ .- ~
WITH HN1225
\ ~~--------_ .:~ ~ --~

~3-~.,"'-
'" 0> ' .· ·- •'-- ~·
"~ \r
\~ - --
I
r
\
~'
" ,
,rti1
n
-11
: I/ :
1 " ~-.., -,...:'\<cl>n:!<::>
~f ~~ ---~ .' n)/~?1
'\ "'- -~ ~
""- ,_,_ "'-:: r- [..,.
~ ('C~ .l)~:=fv2--
~ ~--· ;_; .;
1
;-=--;Q )-;>-'»
I ',
~ ~
~--- ~,'::---- '
. /
//
'-.._._/ I - ,
\ .' . / .' / J
\
\\\<~
\ \\
I- · - - -----
/
·\I ~/i/
('.
-( '
~
~~ ',
CABLE- ACCELERATOR CONTROL
\ \ '
\ \\
Figure 6-12
Throttle Control Cable Routing - L6 Engines.
VALVE ASM . Q.___
SPACER SOLENOID ~T~ SCREWASM. ill
SPRING \
-~
- ~ SPACER
c--:?. ;:;;~ ~~~
:·. , ~-
I ·')- . ~ --, .
L'G
- --Y
, ..
___..-~~
~--
,,----) ~.•
.1-;:
.
---:-> . .,
. . _ \, 0
'-~ ~ ~ BRACKET
~ -- ~ \ ·- •. • ./' THROTTLE
BRACKET
--- ~-- _- 6) RETURN SPRING
\
)..---" \
.Y i ~ 1"
r1 ''
\.!..) BOLTASM . £
DO NOT LUBRICATE THR OTTLE CABLE A SM
DO NO T LUBRICATE THROTTLE CABLE ASM .
VIEW 0 WITH 5 LITRE
VIEW 0 WITH 4 .2 LITRE
rr,~~
s;(- ~ r:J:\1
) (~ _.;;
~-J_!) ~
'- ~
~
~-- --- ~
~ ~
lCjJ
THROTTLE
.·), , ;)"'
_. ( ~·
r ., /--,--) ...:-~
- · )(I- I
{?)~
,/
LEVER
~~-. . . . . . _ --;<
II --J) . ~--~(
'. '·
/7_)~ - .....
· ~
, .. ..~
'
I
1 1
I., ~
-~
----==---..::-- I
I
--\
\ ~=~
.........
IJ -- :;
GROMMET ~~ ', \
m
-- ./
'----, _ / @ z
& 12 - 16Nm
Q) LUBRIC A TE PIVOT POINT WITH HN1225
--- -mz
C)
CJ)
0
0)
I
Figure 6-1 3 1\)
Throttle Control Cable Routing - VS Engines. w
0
0')
I
1\)
~
m
z
G')
-z
m
LSCY=~=
en
1\
1) DEPRESS THR OTTLE PEDAL T O FLOOR
2) AT T AC H THROTTLE CAB LE T O PEDAL LEVER & CARB.
3) ADJUST CABLE NU T S T O FULLY OPE N THROTTLE '-------
VA LVE & T I GHTEN
4) ALLOW THROTTLE PEDAL T O ASSUME FREE POSIT I ON
5) ADJUST SCREW ON LEVER SO TH AT PEDAL HAS NO
FREE PLAY, BUT CABLE ON L Y IS STRETCHED AND
IDL IN G SPEED IS NOT AFFECTE D
Figure 6-14
Throttle Control Adjustment Details.
------ - 0
CAP- ACCELERATOR SUP PORT
HOLES TO L IN E UP WITH PI VOT POINT A WITH 6 CYL.
AND WITH PI VOT PO INT B WITH 8 CYL .
\oa0 / L EVER ASM. - ACCELERA T OR CONTRO L
~S P R I NG
~\_~ SCREW
\~
o ..
PI VOT PO I NT A : CI RCLIP
PIVOT POIN T B (2 PL AC ES)

I
_/
\. \_SPR ING
m
(j) APPLY LITHIUM GREASE HN1225 z
G)
-z
m
en
0
0')
I
Figure 6-15 1\)
Accelerator Control Leve r Insta llat ion Details. 01
06-26 ENGINES
NOTES
ENGINES 06-27 .
COOLING SYSTEM
INDEX
Subject Pag e Subject Pag e
GENERAL DESCRIPTION ............................................... 06-27 RADIATOR PRESSURE CAP ......................................... 06-34
RADIATORS ...................................................................... 06-27 TESTING ..................................................................... 06-34
RADIATOR SHROUD ....................................................... 06-27 COOLING SYSTEM PRESSURE TESTING .................. 06-34
RADIATOR CAP ............................................................... 06-27 RADIATOR ......................................................................... 06-34
RADIATOR COOLANT RECOVERY SYSTEM ............ 06-31 REMOVAL .................................................................. 06-34
THERMOSTAT ................................................................... 06-31 INSTALLATION .......................................................... 06-35
HOSES ................................................................................ 06-31 FAN AND SHROUD ......................................................... 06-35
WATER PUMP ................................................................... 06-31 REMOVAL .................................................................. 06-35
FAN AND SHROUD ......................................................... 06-31 INSTALLATION .......................................................... 06-35
COOLING SYSTEM INHIBITOR ..................................... 06-31 AUXILIARY FAN ............................................................... 06-35
SERVICE OPERATIONS ................................................. 06-33 GENERAL DESCRIPTION ....................................... 06-35
FAN BELT .......................................................................... 06-33 Removal .............................................................. 06-35
FAN BELT TENSION ................................................ 06-33 Installation .......................................................... 06-35
FILLING THE COOLING SYSTEM ................................. 06-33 THERMOSTATIC SWITCH ....................................... 06-35
CLEANING COOLING SYSTEM .................................... 06-33 Remove and Test .............................................. 06-35
REVERSE FLUSHING ............................................... 06-33 Installation .......................................................... 06-36
Radiator ............................................................... 06-33 ENGINE COOLING SYSTEM DIAGNOSIS ................... 06-37
Cylinder Block and Cylinder Head ............... 06-33
Heater Core .......... ......... .. ................................... 06-33
THERMOSTAT ................................................................... 06-33
REMOVE AND TEST ................................................ 06-33
INSTALLATION .......................................................... 06-34
GENERAL DESCRIPTION
Th e coolin g system consists of th e radia tor, radia tor cap,
ove rfl ow rese rvo ir, th ermostat, hoses , wa ter pum p, coolin g RADIATOR CAP
fan , and suitabl e passages for water c ircul ati on th ro ugh th e A press ure/ vent cap is used to all ow a press ure buil d up
engin e.
of 1 00 kPa in th e radiator and bloc k. Thi s pressure raises
th e boiling point of th e coolant to approximately
RADIATORS
1 20 degrees C at sea level.
A c rossfl ow radi ator is used on all Models. Tanks in thi s DO NOT REMOVE RADIATOR CAP TO CHECK COOLANT
type of radia tor are located to th e right and left of th e co re: LEVEL WHILE RADIATOR IS HOT: chec k coo lant vi sually
instea d of above and be low. Refer Figs. 6- 16 and 6- 1 7. Th e at th e see- through coo lant reservoir on th e ri ght hand
fill er cap is situ ated in th e right hand tank on L6 models fend er inn er pan el:
and in the left hand tank on V8 engin e ca rs.
WARNING : THE RADIATOR CAP HAS NO FINGER GRIPS ,
Radia tors used wi th automa tic transmi ss ion models have MAKING IT DIFFICULT TO REMOVE WHEN THE RADIATOR
oil coo lers built into th e rig ht hand tank for L6 engin es and IS HOT. THIS IS BECAUSE THE NORMAL OPERATING
th e left hand tank for V8 with inl et and outlet fittin gs for TEMPERATURE OF THE COOLANT, WHEN IT IS UNDER
transmi ss ion flui d c irculati on. Manu al transmi ss ion equip - PRESSURE IN THE RADIATOR , CAN BE FAR IN EXCESS
ped models utili ze radiators with out oil coo lers. Vehi cles OF ITS BOILING POINT AT NORMAL ATMOSPHERIC
equi pp ed with air co nditionin g use a ra d iato r with extra PRESSURE. REMOVAL OF THE CAP WHEN THERE IS ANY
coo ling capability for greater coo lin g demand s. PRESSURE IN THE SYSTEM CAN RESULT IN IN-
Th e radia tor feat ures pegs attac hed to th e lower frame and STANTANEOUS BOILING OF THE COOLANT, POSSIBLY
th e upper area of each hea der tank. Th ese pegs are used WITH EXPLOSIVE FORCE , SPRAYING SOLUTION OVER
to support the radiator in four ru bber mounts. Th e assembly THE ENGINE , FENDERS AND THE PERSON REMOVING
is held in pos ition by two sprin g c lips at th e upper THE CAP.
mounting locations. Refer Fi g. 6- 16 and 6- 17. Th e press ure/ vent type radiator fi ll er cap co ntain s a blow
off or pressure va lve and a vac uum or atmos ph eri c valve
RADIATOR SHROUD (Fig. 6- 19) . Th e press ure va lve is held aga inst its seat by
a sprin g of pre-determin ed strength whi c h determi nes the
A radiator shroud, Fig . 6- 18 is fitt ed between th e radi ator max imum operatin g pressure of th e system. The vacuum
upper support pa nel and th e front upper edge of th e ra- va lve is held again st it s seat by a li ght spri ng which permit s
diator assembly to minimi ze th e rec ircul ati on of hot air from openin g of th e va lve to reli eve vac uum c rea ted in th e
th e rear of th e rad iator bac k through th e co re as thi s woul d system when it co ols off an d whi ch oth erwise mi ght ca use
impa ir th e coo lin g effi c iency of th e radi ator. th e radiat or to co ll apse .
0
0')
I
1\.)
co
m
z
G')
~- UP PE R HOSE
I SHROUD - EN G INE FAN
-z
m
en
SPR I NG
*MODELS 8VK,8VL & HEAVY DUTY RAD IA T OR
ffi 1.6 - 5 .0 Nm
Figure 6-1 6
Radiator Installation Six Cylinder Models
SHR OUD A SM . EN GIN E FAN 7
~ SCREW & CLAMP ~
(2 PLACES ) (4 PLA CES )

~
-:/ ~
-r
,----- -WYJ
UPP ER HOSE
__} r GASKET
PLUG
~
~
I
~::- ))~ I
SA F ET Y C LI P / :~~A,
f2t. . ' - ,, ."-
(2 PL ACES) .z.__r Q
- '. -1/2;~ "
/'
,-::-..:;
k -;
'---/ (<,.!' yj ~~ -
'----
B U M PER
.( -. ,__
,.//
~-,
~"
(2 PLACES ) ----.._ * PLU G T/
SWIT CH
'- ., ADAPT ER
1__'--
~I
(_ ~~~
LOWER - ~
'/ HOSE ~
BUMP ER _ /
(2 PL A CES)
* MOD E LS 8V K , 8VL & H EAVY DUTY RA DI A TOR

m
z
C')
-z
m
Li_ 3 .6 - 5.0Nm CJ)
0
0')
I
Figure 6-17 1\)
Rad iator Installation VS Models CD
~- \
06-30 ENGINES
1- a:
z w
0 0..
a: 0..
lL ::J
a:
0
1-
<(
0
<(
a:
0
::J
0
a:
I
(/)
/
ENGINES 06-31
c irculation of coo lant through the radiator but al lowm g th e

coo lant to c irculate throughout th e engine to warm it
qui c kly and evenly.
As th e engine beco mes warm , th e pellet expand s and th e
th ermostat valve open s, permi tting the coo lant to flow
through th e radiator where heat is rejected. Thi s open in g
and c los ing of the thermostat valve permits eno ugh coo lant
to en ter the radiator to keep th e eng in e within spec ifi ed
temp erature limits .
HOSES
Cooling system hose fitment is si milar to previous Holden
models. Refer Figs . 6-16 and 6- 1 7 for speci fi c assembl y
details.
WATER PUMP
Figure 6-19 The water pumps on both V8 and L6 are th e same as on
Radiator Pressure Cap previous Holden models. Detai ls of th e se rvi cing and
ove rhaul procedures are in th e approp ri ate sections of th e
HO Holden Serv ice Manual , Vo lume 4, Part Number
M370 18.
RADIATOR COOLANT RECOVERY SYSTEM
FAN AND SHROUD
A 'see- through,' two co mpartment pl asti c rese rv oi r, co m-
bined with th e windshield wa sher co ntainer is co nn ec ted Models with L6 engines use a four blade fan . V8 Mode ls use
to th e radiat or ove rflow by a hose. See Fig . 6-20. As th e ca r the seven blade fan with th e GM th erm ostat ica lly controll ed
is driven, th e coo lan t is hea ted and ex pand s. Th e portion fluid c lutch assembly as stand ard . L6 eng in es with air
of th e flui d displaced by thi s expansion fl ows from th e co nditi oning use thi s same fan . V8 Mode ls with air co n-
radiator into th e rese rvoir. Wh en th e ca r is stopped, and th e d iti oning use a 'F ram ' 7 blade fan with extra blade pitc h
coo lan t coo ls and co ntrac ts, th e d isplaced coo lant is drawn and a GM Thermostati cally controlled fan c lutc h. Air
bac k into th e radiator. Thu s th e rad iator is kept fill ed with cond iti oned models also use an auxili ary electric fan in
coo lant to the desired leve l at all times, res ultin g in in - front of the co ndense r. Thi s fan is co ntroll ed by a th er-
creased coo lin g effi c iency. Coolan t leve l should be be- mostatic swi tch mounted in th e ri ght hand radi ator tank for
tween 'ADD' and ' FULL' marks on reservoir. V8 engi nes and left hand tank for L6.
Fan Shrouds are used on al l models; these assist air fl ow
THERMOSTAT through th e radiator. There are brac kets weld ed to th e
radiato r lower fram e and these fit slots mould ed into th e
A th erm ostat is used in th e water outlet passage on all lower edge of the shroud ; two self tapping sc rews sec ure
engin es to co ntrol th e fl ow of coo lan t, providing fast engin e th e upper edge of th e fan shroud to the radiator. Refer
warm -up and reg ul atin g coo lant temperatures (Fi g. 6-2 1). Figs. 6-16 and 6-17 .
A wax pell et or power element in th e th erm ostat expands
when hea ted and co ntracts wh en coo led . The pellet is COOLING SYSTEM INHIBITOR
co nn ec ted through a pi ston to a valve and , when th e pell et
is heated, press ure is exe rt ed again st a rubber diaphragm Due to the combination of materia ls used in th e coo lin g
whi ch forces th e valve to open. As th e pellet is coo led, th e system , it is esse ntial that on ly th e purest poss ibl e water be
co ntrac ti on all ows a spring to c lose th e valve . Thus , the used to top up th e radiat or.
valve remains closed whil e th e coo lant is co ld , preventing Cooli ng system co rrosion inhibitor to GMH specificat ion
HN 11 09 (emul sifiabl e oi l) is used at vehicle assembly . The
coo ling system should be drained and filled with fres h
FLANGE PISTON
water and th e co rrect volum e of corrosio n in hibitor at eac h
1 O,OOOkm service.
FLANGE VALVE SEAT The co rrect volumes of corrosion inhibi tor are;
SEAL
L6... ............................ ........ .... 170ml
4.2 V8 .... .. ................................. ....... 240ml
5 litre V8 .. .... . .......................... ........ 226ml
FRAME
The appropriate amo unt of inhibitor should be thoroughly
mixed with eight litres of pure water in a clean co ntain er.
Pour thi s into th e radiator and top up radiator with clean
water. Do not leave air space in radiator or coo lan t ove rfl ow
VALVE as return system will not operat e success fully . After making
sure that radiat or cap sea ls are in good conditi on install
ca p and top up overflow rese rvoir to co ld level.
Corros ion inhibitor HN 11 09 makes a tran spa ren t pale
WAX PELL ET RUBBER DIAPHRAGM green fluorescent so lution wh en mixed with water. After
some tim e in the system, thi s may change to an opaque
Figure 6-21 ye ll ow green co lour. Th e app ea ran ce of eith er co lour in -
Typical Cooling System Thermostat. dicates that the system is protected from co rrosion .
0
0')
I
(,)
1\)
m
RADIATOR COOLANT z
RECOVERY HOSE TO G)
TANK ----------~ -z
m
~~~-
VB SYSTEM SHOWN
6 CY L ,
SEE INSERT FOR L6 DETAILS en
' , , ' ~,,,
'\\\-- "\~ ,. ~. ~-~ <-"-'~

{_ ; ;~--~ ~~~!!
.' ~--
\ \
' '\ _/ I I
\_____ - J.-. 1
\ ' ;. ~~~ " \
\ \ \r--- :------ ~ -- -· ./' / / ,, /.'
ov~:~o~\ / \J/~-~1 ~ --- ~ -·

\ '-., ..-,
, L -----
-- . - -'-'J l
--
. .:·, ; ""- At[6}
' '-....'-... •
- =--·
~1 3
1'-,.'- /'):.
•'
- ' ' ~
-.....;.'=\ =-·~· :..·
'i -'=J -~
r
. I·
,,' I,' ----\,
.
.-·~
~ I "---
. . . . . ~'~ .
__.;;.--·- '
. --.)
_ __ _ __ _
·.::' '-
LIJ - - - - -
"',,y ---- ----- (_)
-~-----
<_)i·
G
FU E L BOW L -
R AD IA T OR OV ER FLOW
HOSES
y / ~ HOSE TO PROTRUDE PAST
CLIP APPROX. 20.0mm
VENT HOS E
SECT ION A·A

VIEW [A]
Figure 6-20
Radiator Coolant Recovery System.
ENGINES 06-33
SERVICE OPERATIONS
FAN BELT and scale before reverse fl ush in g the coo ling sys tem. Th ere
are a number of cleaning so luti ons ava il ab le and th e
TENSIONING man ufa cturers instructio ns sho uld be foll owed c losely.
Fan be lt tension is adjusted by moving the alternator on its REVERSE FLUSHING

adj uster brac ket.
Reve rse flu shing shou ld always be accomplished after th e
The belt tensions li sted below are in term s of strand tension system is thoroughly c lea ned.
using a Warren and Brown be lt tension ga uge mode l
Flu shin g is accomplished through th e system in a direc ti on
number, 982350. A full description of the use of thi s ga uge
oppos ite to the normal flow. Thi s action ca uses th e water
is shown in th e Coo lin g System sec ti on of th e HO Hold en
Se rvi ce Manual , Volum e 4, part number M370 18. Higher to get behind th e co rro sio n depos its and force th em out.
Th e system sho uld be reverse flu shed as foll ows.
strand tension is used on 'new ' belts to al low for init ial
stretch which occ urs in the firs t 5 to 1 0 minutes of run ni ng .
Radiator
A belt is conside red to be 'used' aft er 10 minutes of
1. Remove the radiator upper and lower hoses and en-
runnin g. Any re- tensioning of previously insta ll ed belts due
sure th e radiator cap is in place.
to parts repla cement or repair should be at th e 'u sed'
figure. Converse ly any new belt fitt ed aft er repair should be 2. Attach a lead -away hose at th e top rad iator hose
tensioned to 'new' figure . con necti on.
3. Attac h a new piece of hose to th e rad iator lowe r
FAN BELT TENSION co nn ecti on and inse rt th e flu shin g gun in th is hose.
Engin es ................ .... Strand Tension 4. Co nnect th e water hose of th e flu shing gun to a water
New Used outl et and the air hose to an air lin e.
L6 ....... ................. ....... .............. ........ .......... .. .... . .... 90 55
CAUTION: Apply air gradually as a clogged radiator will
V8 ........ ........ .. . ............................ 125 75 stand only 135 kPa pressure.
It shoul d be noted that engin e fan and altern ator bel ts are 5. Turn on th e water and when th e rad iator is full , turn on
run for 1 0 minutes at engine assemb ly and co nsequ ently th e air in short bl asts, all owing th e rad iator to fill be-
are to be cons id ered as 'used ' should any re-tensioning be tween blasts of air.
required at ve hi cle pre-delive ry or se rvi ce. 6. Cont inu e this flu shing un til th e water from th e lead-
away hose runs clear.
FILLING THE COOLING SYSTEM
Und er normal c irc um stances th e coo lin g system is not Cylinder Bloc,_qnd Cylinder Head
topped up at th e radiator fill er; th e level is c hec ked at the 1. With the thermo sta t, t::rTII.J , ~...:, .. : ··' ~" ' 1V hose
rese rvoir and clean water is added as necessary. to th e water pump inl et and a leng th of new hose tv tne - - -
If hi ghe r th an normal engin e temperatures are expe ri enced, thermostat housing outl et co nn ecti on at th e top of th e
wait until th e eng ine has coo led down and c heck th e engine .
coo lant level in th e rad iator. NOTE: Disconnect th e heater hose and cap co nn ecti ons at
engine when reverse flu shing engine.
CAUTION: Do not remove the cap if there is any evidence 2. In se rt th e flu shi ng gun in th e new hose.
of pressure in the system, leave the system to coo l further
3. Turn on th e water and when the engine water jacket
until th ere is no sign of pressure wh en the cap is dis turbed.
is full , turn on th e air in short blasts.
Th e coo ling system is designed to operate safely with 4 . Con tinu e thi s flu shin g until th e water from the lead-
coo lan t temp eratures up to 120 degrees C at sea leve l. away hose run s c lea r.
Wh en th e radiator cap is loose ned th e system pressure
drops to atm ospheric and th e heat which ca used water Heater Core
tempe rature to be higher than 1 00 degrees C will be 1. Remove water outl et hose from heater co re pipe .
dissipated by conve rsion of water to steam. This reac ti on
2. Remove inlet hose from engin e con nec ti on.
will commence instantly and will be wi th explos ive forc e
sprayin g boiling coo lant and steam ove r th e vehicle and the 3. In se rt flu shing gun and flu sh heater co re. Ca re must be
person removing the ca p. taken when apply ing air pressure to preve nt damage
to th e core.
If a large amount of coo lant has bee n lost, determ in e ca use
before top ping up system with water and co rros ion inhibitor THERMOSTAT
mixed to th e speci fi ed streng th .
Repea ted coo lant loss indicates need to chec k th e rad iator REMOV E AND TEST
press ure ca p and seat to ensure that a perfect sea l is being 1. Drain radiator level to bel ow th erm ostat and remove
achieved and that th e cap is fun cti oning co rrectly. Also th e water out let assembly.
coo ling system should be pressu re c hec ked for lea kin g 2. Remove th ermostat. Unless obviously defective, test
hoses, gas kets etc. th erm ostat as follows before replacing with new one:
If ru st and sca le are prese nt in th e system , c leaning and a. Immerse unit and therm ometer in co ntain er of
reve rse flu shin g are requ ired. 50!50 glycol / water over a heater. While heating
water and glyc ol, do not rest either th e ther-
CLEANING COOLING SYSTEM mometer or thermo stat on bottom of contain er as
thi s will cause th em to be at a higher temp erature
A good cleaning so luti on sho uld be used to loosen th e rust th an the glyco l/ water so luti on.
06-34 ENGINES
b. Agitate so luti on to ensure uniform temperature of 4. Slowly apply pressure by pumpin g th e tester until th e
liqui d, th erm ostat and th erm ometer. need le is at th e marked press ure (1 00 kPa) . Th e cap
Thermostat shoul d start to open .07mm at a tempe ratu re shoul d unload slightly above thi s press ure and hold
of 86 deg rees C to 90 degrees C and should be fu lly open pressure at 95 kPa if it is sealin g co rrec tly.
(9 mm or more) at a tempe rature not in excess of
100 degrees C.
COOLING SYSTEM PRESSURE TESTING
INSTALLATION
The fol lowing test may be perform ed with press ure testin g
1. Clean gasket surfaces on water outl et ho using. eq uipm ent avai lable comm ercially for thi s purpose.
2. Install thermostat with pellet or cartridge projecting 1. Fill the radiat or to approximately 25 mm below top of
down into water passage . fill er nec k.
3. Using new gasket, install water outl et fitting . Tighten 2. In stall th e testing equipm ent to th e radi ator (Fi g. 6-23).
bolts to 27 Nm .
3. Apply a test press ure 20 kPa hi gher than th e setting
4. Refill radiat or with water and inhibitor, in stall cap and stamped on th e radi ator cap. i.e. 120 kPa.
top up overfl ow re se rvoir to co rrect level .
CAUTION: When a radiator is under tes t, th ere is no
RADIATOR PRESSURE CAP pressure relief because th e overflow is blocked off. Do not
Radiato r caps in press uri zed coo ling systems are loaded over pressurize the system .
to a defi nite figure whi ch is marked on th e cap . Pressure 4. If th e pressure will not hold , th ere is a lea k in th e
type radiator caps necess itate a fu lly sea led coo ling system coo lin g system .
-a ir lea ks, if present, will defeat th e purpose of the ca p and
ca use loss of coo lant. On th e oth er hand , if th e ca p releases
at a higher pressure than th at reco mm end ed , (1 00 kPa)
th e radiator may be damaged .
CAUTION: To avoid th e danger of being burned, do not

remove radiator cap while engin e and radia tor are still hot,
sca lding fluid and steam may be blown out under pressure.
If
1. Remove radiator cap when engin e is coo l by:
a. Slowly rotating cap co unterc lockwi se to detent.
(Do not press down while rotating).
b. Wait until any res idual press ure (ind ica ted by a
hiss ing so und ) is rel ieved.
_____c__ Attercrrr lilssing ceases, press down on cap whil e
continuing to rotate counte rcloc kwise .
TESTING
The foll owin g test may be performed with radiator testing
equipm en t ava ilabl e co mm ercia ll y for thi s purpose .
1. Make sure th e cap is stamped as reco mmended,
100 kPa .
2. Wet the main valve gasket.
3. Attach th e ca p to the test equipment adaptor Figure 6-23
(Fig . 6-2 2) and sec ure oppos ite end of adaptor to
Pressure Testing Cooling System
tester.
RADIATOR
REMOVAL
1. Disconnect battery negative cabl e at batt ery .
CAUTION: Ensure that coo ling system is not hot and there
is no pressure in radiator.
2. Remove radiator cap and radiat or overflow hose.
3. Remove radiator lower hose to d rain radiat or into
suitab le splash tray.
4. Remove radiator top hose.
5. Wh ere eq uipp ed, disconnect tran smi ss ion coo ler lin es
from radi ator.
6. Di sco nn ect th e evapo rative emission co ntrol hoses
from th e canister and position th em to one sid e. Re-
move radiator front shroud (Fi g. 6- 18) by leverin g up
Figure 6-22
th e four c lips sec uring it to th e radiator upper support
Testing Radiator Pressure cap panel.
ENGINES 06-35
7. Remove the two retainin g sc rews at th e top of th e fan INSTALLATION

shroud and pull up on shroud to remove from lower In stall ati on is the reve rse of remova l ope ration s taki ng ca re
holding brackets. Rest shroud on coo lin g fan .
to note th e foll owing .
8. Using a suitabl e sc rew driver, co mpress and lever th e
1. En sure that fan and space r and, wh ere appli ca bl e, th e
retaining c lips out of th e radiator upp er mountin g
th erm ostati c clutch, are co rrec tl y loca ted before
brackets. Refe r Fig . 6-24. ti ghtenin g attaching parts.
9. Lift rad iator upward s out of lower in sul ators and re- 2. Fan to water pump hub bolt torqu e is 28- 38 Nm . Fan
move rad iator from vehicle . to th erm ostati c clutch bolt torqu e is 12-16 Nm .
10. On air co nditi oned vehic les, di sco nnec t ea rth wire Thermostatic clutc h to water pump hub nut torqu e is
from ra dia tor to front end panel . 27-36 Nm .
3. En sure th at fan shroud is co rrec tl y loca ted on lower
INSTALLATION brackets before upper sc rews are install ed.
Radiator in stall ation is th e reve rse of th e removal opera t- 4. Retensio n fan belt.
ions taking ca re to note the foll ow ing: (Refer Fig s. 6- 16 and
6- 17).
1. Make sure that th e lowe r mounting pin s are co rrec tly
seated in the lowe r support rubb ers. AUXILIARY FAN
2. Ens ure that th e relief c utouts in th e upp er support
rubbers are uppermost before instal ling th e retainin g
GENERAL DESCRIPTION
clips.
All VB Models with opti on C60 factory fitt ed airco nditi oning
3. Fan sh roud must be co rrectl y loca ted on lower
are equipped wi th an auxili ary elec tri c coo lin g fan. Thi s fan
brackets before upp er sc rews are install ed .
is fitt ed in front of the airco nditi onin g cond enser and power
4. Radia tor front shroud is positi oned und er top edge of is suppli ed via a re lay wh ic h is tri gge red by a th erm ostati c
radia tor before c lips are in stal led. Refer Fig . 6- 18. switch in the radi ator hea der tank (Refer wirin g d iag ram in
5. Fill coo lin g system. air co nditi onin g secti on). Th e fan will operat e wh en th e air
6. Co nn ect battery neg ative ca ble , start engin e and c hec k co ndi tion in g is operating and th e rad iator coo lant reac hes
for leaks. a spec ifi ed tempe rature.
Removal
1. Di sconnect batt ery negative cabl e from battery .
2. Rem ove radi ator (See section on rad iator removal) .
3. Remove radiator grill e. Refer radiator grille, removal in
Body Secti on of thi s Manual.
4. Remove air co nditi on in g co nd ense r. Refer co nd ense r
removal in Ventil ation , Hea tin g and Air Co nditi oning
Secti on of thi s Man ual.
5. Di sco nnect auxili ary fan power lead at co nnection to
harn ess (Refer Fig . 6-25) .
6. Remove th e three nuts hold in g fan and bracket as-
sembly to co nd enser support. Refer Fi g. 6-25.
7. Tilt top of auxi li ary fan rea rward s and remove from
und er ra diator upper support pan el.
Figure 6-24
Installation
Removing Radiator Side Mounting Retaining Clip In stall ation is th e reve rse of removal ope rati ons taking care
to note th e foll owing .
1. En sure that fan motor earth lead is co rrec tl y in stal led .
(Refer Fig . 6-25 for detai ls).
FAN AND SHROUD 2. Nuts on in sul ated stu ds are tightened to 3. 1 to 4.1 Nm .
Nuts on fan brackets to co nden se r support are ti gh-
tened to 4.9 to 6.6 Nm .
REMOVAL
1. Disconnect battery negative cab le from battery.
2. Release fan belt tension.
3. Remove th e two retainin g sc rews at th e top of th e fan
shroud and pull up on shroud to remove from lower THERMOSTATIC SWITCH
holding brackets. Rest shro ud on coo lin g fan.
4. On non ai rcond iti oned L6 models remove four bolts Remove and Test
sec uring fan to water pump pull ey hub. 1. Di sco nnect battery negative ca bl e from batte ry.
5. On V8 and ai rcondi ti oned models remove th e four nuts 2. Disco nn ec t leads from thermostati c switc h.
sec urin g th e th ermostati c c lutc h to th e wa ter pump
pull ey hub . CAUTION: Ensure that coo ling sys tem is not hot and there
6. Lift fan and sh roud togeth er off engi ne. is no pressure in radiator.
06-36 ENGINES
\~
BUMPER
( (3 PLACES)
' \\,.__
& NUT
SECT ION A-A
BOLT
NUT
""'-_.,__=Jys;_::;::__.!_ WAS HER
'7~ 4 .9 - 6 .6 Nm
£ 3.1 -4. 1 N m
SECTI ON B- B
Figure 6-25
Auxiliary Fan Installation
3. Drain radiator level to below th ermostati c switch and contacts shoul d close , (lig ht sho uld glow) wh en
remove switc h from radiat or header tank and test as temperature reac hes 96 deg rees C to
fo ll ows: 100 deg rees C.
a. Connect 12V battery and indi cator light in se ri es
with switch terminal s and immerse switch and Installation
th erm ometer in contain er of 50 ! 50 glyco l/ water In stall ation is reve rse of rem oval operations takin g ca re to
over a heater. Whil e heatin g, do not rest eith er note the foll owing .
switch or the rm ometer on bottom of con ta iner as 1. Ensure that switc h seal ing wa sher is in good co nd iti on
th is wil l cause th em to be at a hi gher temp era ture and th at it is co rrectl y positioned wh en insta lling
th an th e glycol / water. swi tch.
b. Agitate glyco l/ wa ter to ensure uniform tempera - 2. Fill radiator wi th co rrect water / inhibitor co ncentrati on
ture of liquid, th ermo meter and swi tch. Swi tc h and fil l ove rflow rese rvoir to co rrec t level.
ENGINES 06-37
ENGINE COOLING SYSTEMS DIAGNOSIS

To avoid needless tim e and cos t in diagn os in g coo ling woul d avoid ove rh eatin g - sa me as for prolonged idl es -
system comp lain ts, th e custo mer should be questioned No. 3. Further diagnosti c chec ks should not be required .
abou t drivin g cond itions that place abnormal loads on th e
5. IF NONE OF THE ABOVE APPLY , GO TO DIAGNOSI S
cooli ng system.
GUIDE
1. DOES OVERHEATI NG OCCUR WHILE PULLING A
TRAILER ? To effectively use this chart, question the owner to de-
termin e which of the following (3) categ ories app li es to th e
If answer is 'YES' - how heavy is trail er? If trail er weight is complaint:
grea ter than 907 kg and ca r is eq uipped with normal duty
1. Hot indication on temperature gauge.
coo ling system, a heavy duty coo lin g system should be
co nsidered . Furth er diag nosti c chec ks shoul d not be re- 2. Boiling
quired . 3. Coo lant loss
2. IS CAR EQUIPPED WITH ADD-ON OR NON FACTORY 1. IF CO MPLAINT IS HOT INDI CATION ON TEMPERA-
FITTED AIR CO NDITIONING SYSTEM? TURE GAUGE
If answe r is 'YES' - was heavy d uty radiato r in stall ed with Wa s high temperatur e reading accompanied by boiling? If
th e system? If not, install heavy duty ai r co nditi on ing ra - answer is 'YES ', go to ove rheating diagnosi s gui de. If
diator for th e car mod el involved (per manufacturer's answer is 'NO ', chec k temperature ga uge and sender unit.
spec ifications). Furth er diagnosti c checks should not be Refer 'In strum ents and Gauges ' in the Electri ca l Section of
required. thi s Manual for detai ls.
3. IS OVERHEATIN G OCCURI NG AFTER PROLONGED 2. IF CO MPLAINT IS BO ILING - go to ove rh eating on
IDLE, IN GEAR, A/ C SYSTEM OPERATING ? di agnos is guid e.
If answer is 'YES' - instru ct owner on driv in g tec hniqu es 3. IF CO MPLAINT IS COO LANT LOSS
that wou ld avoid ove rheating suc h as: Determin e if c ustomer is filling th e system co rrectly . Small
a. Idl e in neutral as muc h as possibl e - in c rease am ounts of coola nt loss through th e reservoir ove rfl ow tube
engin e rpm to get higher air fl ow and water fl ow can be expec ted if cond ition s are seve re. If thi s is th e case,
through radiato r. inst ru ct th e custome r on prop er fill leve ls and no further
b. Turn A/C system off during extend ed idl es if di ag nos ti c c hec ks shou ld be required . If in correc t fillin g is
overheati ng is indi ca ted on temperature ga ug e. not th e problem, go to coo lant loss in diagnosis guide.
Further d iag nosti c checks should not be req uired .
WARNING : THE COOLI NG SYSTEM IS DESIGNED TO
4. IS OVERHEATIN G OCCUR IN G AFTER PROLONGED
OPERATE AT 100 kPa PRESS URE AND TE MPERATURES
DRIVING IN SLOW CI TY TRAFFIC, TRAFFI C JAMS ,
NOT EXCEEDIN G 120 degrees C CAUTION SHOULD BE
PARADES, ETC.?
EXCERCISED WHEN REMOVIN G PRESSURE CAP OR
If answer is 'YES'- in stru ct owner on driving technique that SERVICING THE SYSTEM.
DIAGNOSIS GUIDE - COOLING SYSTEM
OVERHEATING
Cause Remedy
a. Lack of Coolant a. Refill system and check for leaks
b. Fan belt loose or broken b. Adjust or replace
c. Fan belt oi l soa ked c. Replace fan belt
d. Thermostat sti cks closed d. Replace therm ostat
e. Water pump inoperative e. Repair or rep lace water pump.
f. Cooling system clogged f. Clean en tire system and reverse flu sh.
g. In co rrec t ignition timin g g. Re-time engine igniti on
h. Brakes d ragging h. Adjust brakes
i. Rad iator pressure ca p defec ti ve i. Replace ca p
j. Radi ator core air passages blocked with insects, etc. J. Clean ou t air passages
OVERCOOLING
Cause Remedy
a. Thermostat remains ope n a. Replace th ermostat
b. Extreme ly co ld cl im ate b. Cove r part of radiat or area
06-38 ENGINES
LOSS OF COOLANT
Cause Remedy
a. Leaking radiator a. Repair or replace
b. Loose or damaged hose co nn ecti ons b. Tighten or replace hose co nn ec ti ons
c. Leaking water pump c. Repair or replace water pump
d. Leak at cylind er head gasket d. Replace gasket, and ti ghten bolts evenly to co rrect
torqu e
e. Cracked cylind er head e. Replace cylind er head
f. Crac ked cylind er, or block expan sion plug loose f. Make necessary repairs or repl acements
g. Engin e operating at too high temperature g. See over-heating causes
h. Radi ator pressure cap defective h. Replace ca p
i. Radiator overflow not returning to radiator from i. En sure radi ator is co mpl etely fill ed . Ensure overfl ow
overfl ow rese rvoir hose conn ecti ons are sec ure. Ensure rad iator ca p is
sealing on top sea l.
j. Leaking heater unit or hoses j. Replace or repair heater and hoses.
CIRCULATING SYSTEM NOISY
Cause Remedy
a. Water pump seal squealing a. Add co rrec t proporti ons of Co rros ion Inhibitor,
HN11 09 to coo ling system. If not effec tive in
eliminatin g squ ea l, overh aul water pump.
b. Pump bearing s rough b. Repair or repla ce pump
c. Fan blades loose or bent c. Tighten or repla ce tan blad es
d. Fan belt noi sy in pulley d. Dress belt with belt dressing or soap and adju st.
e. Fan belt inner plys loose e. Replace fan belt.
ENGINES 06-39
SPECIAL TOOLS
Too l Name Too l Numb er

Crankshaft Rea r Main Bea ring Oil Sea l In staller .... 6A60
or AU1 00
Rear Main Bea ring Oil Seal Pack in g Too l (Dea ler
Fabri cati on)
AU100
Crankshaft Rear Main Bear ing Oil Seal Installer
~21/2' MINR l_ I
I -
'
® - - J.
I
I ~T
J.
_j
1/ 4"
jt
8" A PP ROX .
.f--'" _L
~/64"
[ ~- <J I
'
- 7/32"
NOT E: RE MOVE ALL SHARP CORNERS

1 / 2" Of A METER BRASS ROD
T
Dealer Fabricated Rear Main Bea ring Oil Seal
Pack ing Tool
06-40 ENGINES

L6 Engines V8 Engines
Nm. Nm.
Bolts - Cylinder Head ... ...... ..... .... ............. .... .... .. ... ........... 1 02 Bolt - Oil Suction Pipe Support & Flange to Cylinder
Bolts- Main bearing (oiled threads) 81-95 Case ... .. ........... .... . 8-1 0
Bolts - Flywheel or drive plate to crankshaft ......... .. 61 -75 Bolt - Oil Pump Cover Assembly to Body ........ 5.6-6.7
Bolts - Water Pump ... .... ........................ .............. . 18 -23 Bolt - Rocker Cover Asm. to Cylind er Head .... 4.5-6.2
Bolts - Fan and Pulley ...... .......... ... .. 23-27 Bolt - Oil Pan Assembly to Cylinder Case ..... ..... 8-1 0
Bolts - Oil pump assembly ............... .. ..... 23-30 Bolt - Timing Chain Damper Assembly to
Bolts - Oil pump cover ..... ........................... 6.8-8 Cylinder Case ...... .......... ................... ... .... ................. ...... 9-12
Bolts - Push rod cove r ....... ....... ........ ..... 8-9 .5 Bolt - Generator to Brace ....... 20-27
Bolts - Engine front mounting bracket (3/8 in .) ..... 34-46 Bolts - Ca rburettor Assembly to Inlet Manifold ....... 20-27
Bolts - Engine front mounting bracket (7 / 16 in.) ... 34-46 Bolts - Fuel Pump to Front Cove r Assembly .... 23-30
Bolt - Starter motor to clutch housing .............. ... ...... 26 -33 Bolts - Oil Pump Assembly to Cy lind er Case .... . . 23-30
Bolts - Ignition distributor clamp ......... ....................... 11 - 16 Bolts - Water Pump Assemb ly to Front Cover ....... 23-30
Bolts - Rocker arm pivot .............. ....... ......... .. .. ... .... ..... 30 -39 Bolts - Water Pump & Front Cover Assembly to
Bolts - Timing cover to cylinder and case .................. 8-11 Cylinder Case ...... 23-30
Bolts - Power plant rear mount. to transmission 34-46 Bolts - Rocker Arm Pivots to Cylinder Head ......... 30-39
Bolts - Power plant rear mounting to Bolt - Crankshaft Pulley to Hub ............ .......... .. .. 30-39
c ro ssmem ber . ................. .... ... .......... ... ..... . ..... 34-46 Bolt - Starter Motor Brace to Cylinder Case .... 23-30
Nuts - Manifold clamp studs . 41 -4 7
Bolts - Water Pump Pulley & Fan to Water
Nut - Front engine mountint assembly
Pump Hub ............... ...... ........ 23-30
to engine bracket bolt ............... .. ....... 18-24
Bolt - Distributor Clamp to Cylinder Case ............... . 20-27
Nuts- Connecting rod (o iled threads) ...................... 27-35
Bolt - Ignition Coil Bracket to Inlet Manifold .. 27-34
Nuts - Exhaust pipe to manifold .............. .... ....... 1 2-16
Bolts - Exhaust Manifold to Cylinder Head .. . 27-34
Spark plugs dry threads ........... ..... ................................... 9-20 Bolts - Inlet Manifold Asm. to Cylind.er Heads ....... 34-40
Screws - Camshaft retaining ............. ......... 4.5-5.5 Bolts - Starter Motor Asm . to Cylinder Case ........... 34-37
Plug - Oil pan drain ....... ........ ... ................ 20-27
Bolt - Generator Brac ket to Cylinder Head .............. 34-40
Plug - 011 pump asse mbly .... 20 - 27
Bolt - Generator to Generator Brac ket . ........ 34-40
Plug- Oil gall ery rear 27 -3 4
Bolts - Main Bearing Cap to Cylinder Case .. 81-95
Screws & Bolts - Oil Pan ............... ... ...... 8-11
Bolts - Cylinder Head (Refer Text) ...... 88 - 102 (20 Bolts)
54 (4 Bolts)
Bolt - Fuel Pump Eccentric to Camshaft .... 61-75
Bolts - Flywheel Assembly to Crankshaft -
Manual Transmission ........................... 75-88
Bolts - Drive Plate Assembly to Crankshaft -
Automatic Transmission ........................... . .... 75 -88
Bolt - Camshaft Locato, to Cylind er Case ..... ...... 68-81
Bolt - Torsi onal Damper Assembly
to Crankshaft ...... .... .. ... ................. . 189 Min .
Nut - Fuel Pump Assembly to Front Cove r .. 23-30
Nut - Connecting Rod Bolt .. 40-4 7
Plug - Oil Gallery Rear .............. . .............................. 27-34
Plug - Oil Pan Drain ..... ... 20-27
Plug - Oil Pressure Regulating Valve
Cap to Oil Pump Cover .............. . .. 34-4 0
0 11 r iller to Oil Pump Assembly ................ . ...... 13-20
Spark Plug Assembly (Dry Thread s) ············· ·· ........... 9-20
Thermal Vac uum Swi tches 20-27
Connector, Vacuum Source to TVS ... 11 - 14
Oil Filter Adaptor in Oil Pump Cover ..... 27-34
Clutch Cover & Press ure Plate
Assemb ly to Flywheel ...... .. .. 40-4 7
CLUTCH AND TRANSMISSIONS 07-01
SECTION 07
CLUTCH AND TRANSMISSIONS

Subj ec t Pag e
CLUTCH .............................................................................. 07-01
MANUAL TRANSMISSIONS ........................................... 07-11
TRIMATIC AUTOMATIC TRANSMISSION .................... 07-21
TURBO HYDRAMATIC 400 AUTOMATIC
TRANSMISSION ................................................................ 07-41
CLUTCH
INDEX
Subjec t Page Subj ec t Page
GENERAL INFORMATION .............................................. 07-01 CLUTCH PEDAL ............................................................... 07-03
MINOR SERVICE OPERATIONS ................................... 07-02 REMOVAL .................................................................. 07-03
CLUTCH CONTROL ADJUSTMENTS ........................... 07-02 INSTALLATION .......................................................... 07-03
PRIMARY CLUTCH ADJUSTMENT ....................... 07-02 MAJOR SERVICE OPERATIONS .................................. 07-09
MC6 Torquemaster Transmission .................. 07-02 CLUTCH ASSEMBLY - L6 & V8 ................................... 07-09
M20 and M21 Transmissions .......................... 07-02 REMOVAL .................................................................. 07-09
CLUTCH CONTROL CABLE ADJUSTMENT ....... 07-03 INSPECTION .............................................................. 07-09
CLUTCH CONTROL MECHANISM INSPECTION ....... 07-03 INSTALLATION .......................................................... 07-09
CLUTCH CONTROL CABLE .......................................... 07-03 TORQUE WRENCH SPECIFICATIONS ........................ 07-10
REMOVAL .................................................................. 07-03
INSTALLATION .......................................................... 07-03
GENERAL INFORMATION
Sing le plate dry d isc clutches are used with all manual establi shed to suit th e pull fork system.
tran smissio ns. The clutches are of th e co nventi onal dia - There are three different size clutches used in th e VB
phragm sp ring type, bo lted to th e flywh ee l, and enclosed Seri es:
in a ho usin g attac hed to th e transmi ss ion. Clutch operation
21B mm (B.6 in .) diam eter for L6 engines
on all models is by cab le d irec tl y co nn ec ted to a pu ll fo rk
th rowo ut lever. The th rowo ut bea ri ng is a constant mes h, 229 mm (9 in .) d iameter for 4 .2 VB engines
self aligning type. There are d ifferent bea rings used for L6 25 4 mm (1 0 in.) d iameter for 5.0 VB engi nes
and V8 engin e type c lu tches. Clutch pedal rati o has been
07-02 CLUTCH AND TRANSMISSIONS

CLUTCH CONTROL ADJUSTMENTS
NOTE: Under no circumstances should the clutch be op-
erated after installation of a new pressure plate, driven
plate, flywheel , throwout bearing or clutch cab le without
first attending to the clutch control adjustments, as damage
may occur to th e pressure plate diaphragm.
The clutch con trol on VB Models operates without clutch
pedal free travel, adjustment procedure is as follows.
PRIMARY CLUTCH ADJUSTMENT

The primary clutch adjustment can on ly be carried out with
the transmission removed.
MC6 Torquemaster Transmission

Before installing the transmission to the eng in e, assemble
the ball stud to the clutch housing and adjust to the
mm dimension shown in Fig. 7-1. Tighten lock nut to
25-34 Nm . Lubri cate the ball socket of the clu tch fork with
Molybdenum Disulphide graphite grease to GMH
Specification HN1190 and install on ball stud. - - DIAPHRAGM
FINGERS
M20 and M21 Transmissions

Before in stalling the transmission to the clutch housing ,
lubricate the ball socket of the clutch fork with Molyb -
denum Di sulphide graphite grease to GMH Specificati on
HN 11 90 and install the fork and the clutch throwout
bearing.
Using a spare clutch gear, front bearing and front bearing I
I
CLUTCH
retainer as a mandrel to co rrectly align the throwout fork
and bearing in in housing, gently push the fork forward until
FORK ~ -t J
the throwout bearing contacts the pressure plate dia-
phragm fingers . Measure the distance from the rear face
of the clutch housing to the clevis hook in the fork, (Ref
dimension 'A' Fig. 7-2). The correct dimension is 39 mm )
for clutches on L6 engines and 48 mm for clutches on V8
eng in es. Adjust the ball stud to ach ieve the appropriate
c
dimension . There is a sc rewdriver slot in the rear face of A - -1 D I M 'A' FOR 6 CYL. 39.00 mm
8 CYL. 48 .00 mm
the ball stud to enab le adj ustm en t of th e stud . When th e WITH THROWOUT BEARING I NSTALLED IN FORK
specified distance is ac hi eved, tighten th e loc k nut to AND CO NTACTING THE DIAPHRAGM F INGER S,
25-34 Nm . ADJUST BALL STUD TO ACHIEVE D I M ' A '
THEN TIGHTEN LOCK NUT AGAINST BOSS
TO 25 · 34 Nm.
Figure 7-2
Primary Clutch Adjustment - M20 & M21 Transmissions.
CLUTCH FORK
RETAINER
STUD -CLUTCH
FORK BALL
LUBRICATE BALL SOCKET OF
CLUTCH FORK WITH HN-1190
APPLIED BY BRUSH BEFORE
ASSEMBLY OF STUD ------<'\------=:.....,~~....:::::;~
BEFORE ASSEMBLING TRANSMISSION

TO ENGINE. SET THE CLUTCH FORK BALL
LOCK NUT .&
STUD TO THE GIVEN D IMENSION AND
SECURE WITH LOCK NUT
& 25 - 34 Nm
Figure 7-1
Primary Clutch Adjustment - MC6 Transmission
CLUTCH CONTROL CABLE ADJUSTMENT CLUTCH CONTROL CABLE

NOTE: It is essential to carry out clutch control cable
adjustment befo re the c lutch is operated to avoid c lutch REMOVAL
diaphragm damage. For component part identification, Refer Figs. 7-4, 7-5 or
Clutch ca bl e adj ustm ent procedure is the same for all 7-6
Mod els irrespective of th e c lutch type or transmission in- 1. Jack up vehicle and place on jack stand s.
vo lved. With th e primary clutch adjustment set as de-
2. Release sleeve on outer cab le lower end fitting at
sc ri bed prev iously, th e cab le is adjusted to obtain a
flywheel housing to enable the clevis to be unclipped
spec ifi ed di stan ce between th e clutch pedal and floor pan .
from the clutch fork. On V8 Models, remove the clutch
The ca bl e should be adjusted as follows:
cable to frame spring.
1. Ligh tly load the c lutch fork so that the throwo ut bearing
3. Under the vehicle , use a screwdriver to unclip the
co ntacts th e diaphragm fingers .
clutch housing opening shield from the c lutch housing.
2. Adj ust th e sleeve on th e outer cable lower end fitting
4. Disconnect the lower cab le clevis from the clutch fork
to ac hi eve a 168 plus or minus 2 mm dimen sio n from
and withdraw the cab le through the flywheel hou sing
clutch pedal to fl oor pan. Refer Fig. 7-3. The
lug toward the front of the vehicle.
measurement must be made with th e rubber trim pad
removed from th e pedal . Figs. 7-4, 7-5 and 7-6 show 5. Rem ove clutch ped al as outlin ed in the next item and
th e clutch ca ble in stall ati on detail s for th e variou s withdraw the cab le assembly through the dash panel.
tran smi ssio n and eng in e comb inati ons involved .
INSTALLATION
For co mponent part identification, Refer Figs. 7-4, 7-5 or
CLUTCH CONTROL MECHANISM 7-6 .
INSPECTION In stallation proced ures are th e reverse of the removal.
There are several item s whi ch aff ect good clutch operati on, CAUTION: Note the precise location of the washers
th erefore it is necessary befo re performin g any major grommets etc., at each end of th e cable.
clutch se rvi ce, to make prelimin ary inspections to de - Lubri cate both c levis contact areas with Molybdenum
termin e wh eth er th e troubl e is actually in the c lutch. Di sulphi de grease to GMH Specification HN1271 .
1. Check co ndition of th e cabl e and ensure co rrect
NOTE: Before the cl utch is operated, ensure that c lutch
co mponent assemb ly.
co ntrol cab le adjustment is carried out as detailed pre-
2. Check condi ti on of clutch pedal bushes and shaft. viously .
3. Check clu tch pedal height and contro l cab le adjust-
ment as previously outlined.
4. Check cond iti on of all engine and transmission
mountings.
CLUTCH PEDAL
REMOVAL
For component part identifi ca ti on, Refe r Fig. 7-7, L6 en-
gines or Fig. 7-8 for V8 engines.
1. Ca rry out operations 1, 2 and 3 and as outlined in

cl utch con trol cable removal.
2. Disco nnect the lower cab le clevis from the clutch fork.
3. In side th e vehi c le remove the instrument panel lower
cove r and right hand demisi duct.
4. Unhook the clutch pedal return spring from the pedal
support.
5. Remove the clutch pedal mounting shaft washer.
6. On all Models, remove the pedal mounting shaft toward
the centre of the car.
7. Lower pedal and unhook cable upper c levis from its
location in the pedal.
8. Remove the pedal and return spring assembly.
168,0±2,0 mm
INSTALLAT!ON
Installation procedures are th e reverse to th e removal with
attention to the following . Lubricate the surfaces indicated
in Figs. 7-7 and 7-8 with Molybd enum Disulphide grease
to GMH Specification HN12 71.
NOTE: Before the clutch is operated ensu re that clutch
Figure 7-3 co ntrol ca ble adjustment is carried out as detailed pre-
Clutch Pedal Height Dimension - All Engines and Transmissions viously .
0
.......
I
0
~
(')
I GROMM ET ( I d~
~-GROMME T / -: : ;: : : - -4
(')
:I:
\\\ ~/:c~ 'rq

)>
z
PE DAL
-- r(\_ ~--
c
PEDAL
STA ND AS M.
STA ND I NNE R
WASHER
. \'- \ ((j;~( )
<:.,,-- ~
\~ :; - -,(
~»·
~--
:. ~ l II I 1-4
::c
)>
\~ ~~
G- -~"(~'-
1 \ !JI aJ '-
DAMPER~
INSULATI ON \ I ; ; ;·
', - '->:::::J ;-:-:-.:: I z

~
\-- - "
\ A '(
A~o -
; ';
c··)/' (J)
VIEW~ s::
1
\ ,
' e
~ -------
- ~ --- '-" , ~ )
;.~ \
\ I '- \.::::-,
I
, , '1 ' (
I '
r,_ ,'-
,.. ,.. /')
_/ , ·
... , I
(J)
' ~\
1 (J)
\
\\ \\
·------
-- -
1- - - -._.-- \I 0
\\\\ ), (}, ' \ z
' ); \' , ,// ~ \ (J)
;; '-, \'''}
( :· j; ~/ \
\ \ (( -- \
\ \~-"d CA BLE ASM ./ I I

I
\\ I
\
I
\
\ ~\ \
' \ ' \
z
~ ~.,\\
' SHIE L D-CLUTCH HSG . OPENING
VIE W lA! 6) COAT C LE VIS PIN W ITH

L __ __ AD JUST SLEE V E ON CABL E EN D FITTIN G, T O A C HIE V E
CLUTCH PED A L POS ITI ON AS SHOW N O N FI G. 7-3.
MO L Y- D ISULPHI DE GREASE H N- 1271
Figure 7-4
Clutch Cable Installation Details - L6 Engines with M20 Transmission
/ GROMMET
I
WASHER
PEDAL ~~ll ""'-'
STAND INNER
INSULATION "'fi...('
WASHER _ /L
VIEW IA) '::1:::: ~
CABLE ASM. 0
r-
c
I \\ ~
~ \1 0
~\
. \ \\ ::I:
\ I l
)>
z
\\\\\ c
~
::0
)>
z
CJ)
d) COAT C LEVI S PIN WITH ADJUST SLEEVE ON CABLE END FITTING , TO ACHIEVE 3:
MOLY-D ISULPHI DE GREASE H N -1271 CLUTCH PEDAL POSITION AS SHOWN ON FIG. 7-3 . u;
~
0
z
CJ)
0
.......
I
Figure 7-5
0
Clutch Cable In stallation Details - L6 Engines with MC6 Transmission U1
0
.......
I
0
~
(")
r-
~ ~-1.
~,~1 \ GROMMET
GROMM ET
c
-1
(")
:I:
~
PEDAL
-
-........: ::---....
~"':::: ............:: .........
~"'4._....__ "":::::. ~
~
!
)>
z
ST AND A SM. 0
PED A L -1
STA ND INNER :::JJ
I N SULATI ON )>
z
CJ)
WASHER
s::
CJ)
CJ)
0
z
CJ)
INSER T - C L UT CH HOUS I N G
SPR IN G
NOTE : A SSEMBL E SP R I NG
THROU G H SLIT OF G R O MMET
N H IC H MUST BE AT B OTT O M .
SHIELD - CLU T C H
HOUS I NG O PE N I NG
VIEW IAI A DJUST S LE EVE ON CAB LE

EN D FIT TING TO AC HIE V E
C LUTCH PE DA L POSI T ION
6) COA T C LE V IS PI N WI T H AS SHOWN ON F IG. 7 · 3 - - - . . . l
MO L Y -DI SULPHIDE GREASE HN-127 1
Figure 7-6
Clutch Cable Installation Details - V8 Engines with M20 or M21 Transmissions
\ ~ " ~-=- ~
\ \ ~; '\
\\ \,\' ~\\ ',
~\ ~~~\ ' /n~
\
/ \
f\/
\';,
~ Ji~: .)!
\ \, I " I ,
C : '>
G
PEDAL MOUNT) NG SH AFT
BU FFER
I
/
/
;' ~~\ ~~
/ 1/,',1 \ ~~_\/
G )
@
~'- ! ,"\,
l;''"-fi ' , -'~
\
~\
I ""~
,~
I
' / /IJ}-,
~"
,\ ~~~
I I
\
'\
I
I
I ,, \ , :\ l)}
L~ WASHER
SPR ING -CL UT CH PE DAL
(")
r-
PED AL ASM. - CL UTCH CONTR O L
~J:
)>
z
c
IMPORT AN T :- T O AVOID CLUT CH DAMAGE -4
DO NOT OPERATE CLUT CH PEDA L UN T IL :IJ
A DJUSTMENT PROCEDURE HAS )>
BE EN COMPLETED . REFER FIG. 7 - 3. z
tJ)
PA D-CLUTCH
PED AL TRIM 3:
(!)COAT ALL SURFACES WITH H N- 1271
(j)
tJ)
6
ztJ)
0
.......
I
Figure 7-7 0
Clutch Pedal Installation Details . L6 Engines with M20 or MC6 Transmissions .......
0
......
I
0
\
I
co
(")
~ v:: /~ r
c
-t
\ (")
'\ :I:
~~ (
\\ \{] \\\ :~\(\iri',-~ ~ \
)>
z
c
-PEDAL MOUNTING SHAFT 0
.·
. \\- ~:NG
~~.
J'
,,
~\
',. -t
JJ
)>
z
en
s::
-____.
'
I
.
\ ~
I
~
-- 'v
~~
I
enen
\
I
I ~ BUFFER 0
I z
en
~-
'\_ WASHER
' - sPRING CLUTCH PEDAL
IMPORTANT: TO AVOID CLUTCH DAMAGE

DO NOT OPERATE CLUTCH
PEDAL ASM. PEDAL UNTIL ADJUSTMENT
CLUTCH CONTROL ...-// PROCEDURE HAS BEEN
COMPLETED .
~ PAD - CLUTCH
· PEDAL TRIM
& COATALLSURFACESWITHHN1271
Figure 7-8
Clutch Pedal Installation Details - V8 Engines with M20 or M21 Transmissions.

CLUTCH ASSEMBLY - L6 AND V8 Ti gh ten the bolts grad ually and in rotation to avoid
cove r distortion. Finally tighten bo lts to 41-56 Nm
REMOVAL torqu e and remove pilot tool.
1. Remove transmission assembly as outlined in thi s 4. With MC6 tran sm issions, carry out the primary clutch
sec tion . adjustment as outlin ed previously in thi s Sec tion . Pac k
the recess inside th e throw out bearing and smea r th e
2. On VB Models, remove th e start er motor, remove clutc h
throw out fork contac t area with wheel bearing grease
housing cove r attaching screws and remove cove r. to GMH speci fi ca ti on HN122B.
3. On L6 Models with M20 transmission, remove th e
IMPORTANT : Use no more than .1 0 gram of grease on fork
clutch hou sing cover attaching sc rews and remove
co ntact area and 1 .5 to 2 grams in recess. Refe r Fig. 7-1 0
cover.
for detai ls.
4. On vehicle with M20 and M21 tran smi ss ion, spring th e
clutch fork from th e c lutc h fork ball and remove th e 5. With all type tran smi ss ions, lubri ca te th e ball stud and
clutch throwout bearin g and fork clutch fork bearing with Molybd enum disulphide
grease to GMH specifi ca tion HN1190 and install
CAUTION: Do not drop throwout bearing. Handle with ca re c lutch fork on fork ball .
to avoid damage to races. 6. With M20 and M21 tran smi ssions, carry out th e
5. In stall clutch cen terin g too l to support the c lutch plate . primary c lutc h adjustm en t as ou tlined previously in
6. Mark the flywheel and c lutch press ure plate cove r to thi s Section. Install th e transm iss ion as outlin ed in thi s
facilita te co rrect location when in stalling so that Section, after ens uri ng that th e c lutc h gear splin es and
balance will be maintain ed. throwout bearing are lubri ca ted as outlined in item 4
7. Loosen th e clutch pressure plate cove r attac hin g bo lts above. Refer Fig . 7- 10.
a littl e at a tim e in rotation to avoid distortion and 7. Adjust clutc h co ntrol ca ble as outlin ed in this Section .
remove the clutch assembly and driven plate.
B. On ve hi cles with MC6 transmission, sp rin g c lutc h fork
from clutch housing and remov e throwo ut bearing and
fork.
9. In spect th e clutch pilot bushing for wea r and if
necessary remove, using Too l No. 6A22-2 as shown in
Fig. 6 'Clutch Section' , Volume 4 of th e HQ Holden
Se rvice Manual.
NOTE : Do not remove bushing unless inspection reveals
that it must be replaced.
INSPECTION
1. In spect fork ball soc ket and ball stud for wear. Rep lace
if necessa ry . Check fork retaining spring for damage
or distorti on.
I
I
2. Chec k throwo ut bearing for roughn ess of signs of wear.
Repl ace if necessary.
- A
J_ B I
NOTE: Different throwout bearing s are used for L6 and VB
engine cl utc hes. Re fer Fi g. 7-9 for bearin g identifi ca ti on
detail s.
l
3. Inspect flywheel and clutch pressure plate fri cti on
areas for scoring.
4. Inspect clutch driven plate for lining wear or broken APPLICATION A±0,4 mm B
hub springs.
L6 ENGINE
28,0 mm 20,75 mm
WITH MC6 & M20
V8 ENGINE
36,25 mm 12,5 mm
INSTALLATION WITH M20 & M21
1. If th e clutch pilot bushing was removed, install the new
bushin g as shown in Figs. 9 and 1 0 'C lutch Section',
Volum e 4 of th e HQ Holden Service Man ual. After
installation, place one drop of SAE 90 gear oil on th e Figure 7-9
bushin g. Clutch Throwout Bearing Identification Details.
2. Assemble th e clutch d ri ven plate, together with the
cove r and pressure plate assemb ly and insert c lutch
cen terin g tool into th e pilot bearing through the driven
plate.
NOTE: Driven pl ates are marked to indicate 'gearbox side'.
3. Lin e up th e marks on the pressure plate cover and
flywh ee l and in sta ll th e pressure plate attaching bolts.
APPLY .50 GRAM MAX . OF WHEEL

BEAR IN G GRE ASE HN 1228 MUST BE
D IST R IBUT ED EVENLY & THINLY OVER
WHOLE SPLINE SURFACE FOR THIS DISTANCE-
~- 44 ,5 mm _ __.,.,_...,
Fl LL GROOVE ON L Y WITH 1.50/ 2.00

GRAM OF WHEEL BEARING GREASE H N 1228
A S SHOWN
Figure 7-10
Clutch Throwout Bearing Lubrication Details

Nm
Cl utc h housi ng to c rankcase sc rews- MC6 trans .... 6 1-7 1
Transm iss ion asse mbly to clutch hous ing
M20 & M21 transmissions ... ................... ... . ..... ..... ........ 40-48
Clutc h assembly to flywh ee l sc rews - All ................. 41 -5 6
Ball stu d lock nut - All ..... ............................................. 25-3 4
MANUAL TRANSMISSIONS
INDEX
Subject Page Subj ect Pag e
GENERAL INFORMATION .............................................. 07-11 MAJOR SERVICE OPERATIONS .................................. 07-15
MINOR SERVICE OPERATIONS ................................... 07-13 M20 & M21 TRANSMISSIONS ....................................... 07-15
M20 & M21 TRANSMISSIONS ....................................... 07-13 TRANSMISSION ASSEMBLY .................................. 07-15
GEARSHIFT LINKAGE ADJUSTMENT ......................... 07-13 Removal .............................................................. 07-15
GEARSHIFT MECHANISM OVERHAUL ....................... 07-13 Installation .......................................................... 07-15
DISASSEMBLY .......................................................... 07-13 MC6 TORQUEMASTER TRANSMISSION .................... 07-18
REASSEMBLY ........................................................... 07-13 TRANSMISSION ASSEMBLY .................................. 07-18
MC6 TORQUEMASTER TRANSMISSION .................... 07-15 Removal .............................................................. 07-1 8
TRANSMISSION CONTROL ASSEMBLY ............. 07-15 Installation .......................................................... 07-18
Removal .............................................................. 07-15 SPECIFICATIONS ............................................................. 07-20
Disassembly and Reassembly ....................... 07-15 TORQUE WRENCH SPECIFICATIONS ........................ 07-20
Installation .......................................................... 07-15
GENERAL INFORMATION
Four speed manual transmissions are available either as NOTE: Trimatic Automatic Transmi ss ion is base equipm ent
standard eq uipment or as prod uction options on VB Series. on 8VL wi th 3300 engin e, and 8VX with 4.2 engin e.
Each transmission has floor shift co ntrol and syn-
chromeshon the forwa rd gears. The following cha rt sets ou t B Base (Standard equipment)
manua l transmission application . A Available as a Production Opti on
NA Not Available .
ENGINE TR ANSMI SSION MODEL
M2 0 and M21 transmi ss ions are simil ar to co rresponding

8 8 8 assembl ies released for Hold en HZ Series. The MC6
v. v v Torqu emaster tran smiss ion is simi lar to the assembly fitted
K L X to UC Se ri es vehi cles with L6 engines i.e. 3.5:1 fi rst gear,
and aluminium extension housing .
2850 M20 (3.05 : 1 First gear) B NA NA
3300 M20 (3.05 : 1 First gear) A A A
4.2 M20 (3.05 : 1 First gear) A A A
5.0 M21 (2.54 : 1 First gear) A A A
....
0
-...I
.....
I
KNOB
RETAINER ~ BOOT
"'r-
(")
~
~
DIAPHRAGM- ,.
I
. , ,,, ;,
•
.--.~
~
:I:
SEAL - c;?E;r~ .. :t>
z
ASSEMBLY OF SEAL AND c
BOOT TO RETAINER ~
:::0
:t>
APPLY A BEAD OF SEALER HN-1075 ALONG FLANGE
AT HOLE CENTRES TO SEAL BETWEEN BOOT z
CJ)
RETAINER AND FLOORPAN.
3:
c;;
CJ)
0
z
CJ)
SEAL -
GEARSHI FT
CONTROL
\..--'
3rd & 4th GEARSHIFT CONTROL ROD
1st & 2nd GEARSHIFT CONTROL ROD
ffi 20- 28,5 Nm cV APPLY GREASE HN 1271 TO BEARING SURFACES
Figure 7-1 1
Gearshift Linkage Installation Details - M20 and M2 1 Transm issions.

M20 AND M21 TRANSMISSIONS NOTE: To maintain th e co rrect attitud e of th e gea rshift rods
when insta ll ed , th e adju stm ent must be made in in crements
Min or Se rvi ce Operations fo r M20 and M2 1 tran smi ssions of one complete turn .
are th e sam e as outlined in the appropri ate section of th e 8. Remove Too l No. 7 A 15, and chec k operati on of
Hold en HO Se rvice Manual , Volum e 3, with the excepti on back-up lamps.
of th e followin g:-
9. Reinstall gearshift leve r d iaphragm, boot, conso le and
gearshift lever kn ob. Refer Fi g. 7-1 1 for d iap hrag m,
GEARSHIFT LINKAGE ADJUSTMENT and boot installation detail s.
For id entifi ca ti on of co mponent parts, Refer Fig . 7- 11
1. Remove the kno b from th e gears hift leve r. GEARSHIFT MECHANISM OVERHAUL
2. Remove th e co nso le (refer 'Body, Sheetmetal, Radia tor Fo r identification of component parts, Refer Fig. 7- 13
grill e and Bump er Bars' secti on of th is Manual for
detail s).
3. Remove th e gea rshift boo t and d iaphrag m by leve rin g DISASSEMBLY
from lip of boot retai ner. Care shoul d be taken not to 1. Grip th e forward end of th e transmi ss ion co ntro l
damage th e sea l whi c h wi ll rema in attac hed to th e mountin g in a vice .
tran smi ss ion extension . 2. Remove th e c irc li p retain ing the co ntrol lever shaft.
4. Und er th e vehi cle, remove the retain ers sec urin g th e 3. Ca refull y remove shaft from assembly taking ca re to
1st and 2nd, 3rd and 4th and reve rse gea rshift rods to ensure th e reve rse lockou t spring is c lear of th e shaft
th e selector leve rs on th e mounti ng and leve r as - rebate and does not fou l in the yoke assembly.
sembly. 4. Place gea rshift lever in the reverse shift posi ti on and
5. Locate th e gearshift lever in th e neutral pos iti on th en withd raw all leve rs from mountin g.
install ga uge Tool No. 7 A 15 in the selecto r slots as 5. Inspect all components for wea r and repl ace if
shown in Fi g. 7- 1 2 necessa ry.
6. With th e transmi ss ion shi ft levers in th e neutral pos iti on
and th e se lec tor leve rs ali gned wi th Too l No 7A 15, REASSEMBLY
ad ju st th e truni on on th e reve rse rod so that th e tru nion 1. Lub ricate all bea rin g and friction surfaces with
enters th e hole in th e extern al leve r. Molybd enum Dis ul phide grease to GMH specification
7. Ad ju st 1st and 2nd and 3rd and 4th gea rshift rods in HN1 27 1.
th eir adj usters so th at th e hole in th e rea r end of eac h 2. Assemble the first and seco nd, third and fourth, and
rod can be in stall ed free ly onto th e pin of th e appro - reve rse shift leve rs, together with th e leve r and yo ke
pri ate se lector lever. In stall th e rod retain ers. assembly.
TOOL No . 7A1 5
Figure 7-12
Aligning Selector Lever Slots - M20 and M2 1 Transmissions.
0
......
I
......
=- ~-;
- r-o~J
~
/~ PRELOAD
IQ ) r-
I h
I~- --------lIII II ~:::z::
i~ lL_j SHIMS
)>
A-A z
SECTION
c
~
::x:J
)>
z
en
s::
en
en
SLEEVE
0
z
en
A
A
3rd & 4th SHIF T LEVER
PRELOAD
3rd & 4th SHIMS
SHIFT LEVER
Figure 7-13
Gearshift Mechanism Component Part Identification - M20 and M21 Transmissions
3. Sli de th e assemb ly into th e transmission co ntrol 2. Remove the co nso le refer 'Body, Sheet Metal , Radiator
mounting and in stall th e preload shims as shown in Grill e and Bumper Bars' secti on of thi s Manu al for
Fig. 7-3. detail s.
4. Lin e up th e leve rs and preload shim holes, with th e aid 3. Remove the gearshift boo t by leve ring from li p of boot
of a 5/ 8 in. diameter tapered end rod , and gentl y pu sh retainer. Rem ove diaphragm from recess in sea l. Refer
co ntrol shaft through th e first three levers . Sec tion A-A Fig . 7- 14.
NOTE: Do not hamm er th e shaft through th e leve rs beca use NOTE: Do not remove seal unl ess it requires repl acement.
damage to th e shaft, wa sher, and leve r bores, will occ ur. Rotate sea l suffi c iently to ga in access to co ntrol assembly
5. Place th e gea rshift co ntrol lever in th e third and fourth attaching bolts.
neutral posi ti on and install th e reve rse loc kout spring 4. Remove th e three co ntrol assembly attaching bolts and
and pla sti c sleeve. remove the assembly, seal and gasket from th e
6. Depress th e reve rse loc kout sprin g while pu shing transmi ss ion extension .
through th e co ntrol leve r shaft far enough to retain
sprin g. Disassembly and Reassembly
7. Back out shaft suffi c iently to insta ll reve rse leve r For details of co ntrol assembly disassembly and
preload shim as shown in Fig . 7- 13. reassemb ly, Refer ' 4-speed Torqu emaster Se rv ice Man ual ',
8. Push control leve r shaft into final brac ket hole and Part Number M3760 1.
assembl e retaining c irc lip. Adj ust shift linkage as
outlin ed in thi s sec ti on. Installation
Installati on procedures are th e reve rse to remova l. Refer
MC6 TORQUEMASTER TRANSMISSION Fig. 7- 14 for detail s.
TRANSMISSION CONTROL ASSEMBLY
Removal
1. Remove th e kn ob from th e gearshi ft leve r.

th e extension from dripping on to th e fl oor.
M20 AND M2 1 TRANSMISSIONS
10. Remove electrical cables from back-up light switch,
Major Se rvice Ope rations are th e sa me as outlin ed in the (Fig. 7 -15) and ca ble from TCS switc h.
appropriate sec ti on of th e Holden HO Se rvice Man ual, 11 . Place a block of wood und er th e oi l pan and support
Volum e 3, with th e exce pti on of th e foll owin g:- weight of engin e with a liftin g jack.
12 . Remove th e two bo lts attaching th e engin e rear
TRANSMISSION ASSEMBLY
mounting to the engin e rear c rossmember.
Removal 13. Fold back the lock plates and remove th e two engin e
rea r c ross memb er to fram e bo lts and wa shers. (Refer
1. Di sconn ec t th e exhau st pipe(s) from th e manifold(s).
Fig . 7 -16). Rem ove th e c ro ssmember.
2. Unsc rew th e knob from th e gearshift lever. Remove th e
co nso le (Refer ' Body, Sheet Metal , Radiator Gri ll e and 14 . Remove the tran smi ss ion to clutch housin g attachi ng
Bumper Bars' Sec ti on of thi s Manual for detail s) . bolts.
3. Remove th e gea rshift boot by leve rin g from lip of boo t 15. Withdraw th e transmi ss ion assembly from housi ng.
retai ner. Remove d iaphragm from recess in seal. Refer NOTE: Keep the tran smi ssion assembly supported so that
Fig . 7- 11 . it will not tilt in relation to th e engine until the c lutch gea r
4. Raise th e vehic le front and rea r and support it on jac k splin e is clea r of the clutch plate. If the transmissio n is
stand s. all owed to 'hang' on the splin es, the c lutch will be dam-
5. Remove th e lower rear extension attachin g bo lt whi ch aged .
also se rves as a drai n plug, and drain th e transmiss ion
oil.
Installation
6. Di sco nn ec t th e 1st and 2nd, 3rd and 4th gearshift rods In stall ati on proced ures are th e reve rse to remova l notin g
from th e transm iss ion sel ector leve rs and th e reverse th e fol lowing.
shift rod from th e leve r on th e transmi ssio n rear ex- 1. Before installing transmi ss ion, ca rry out th e primary
tension. c lutch adj ustm ent as outlin ed in 'C lutch' in thi s Sec-
7. Rem ove th e three bolts re taining th e gearshift moun - ti on.
ting and leve r asse mbly to th e transm ission rea r ex- 2. Ti gh ten attac hin g bo lts and nuts 10 th e va lues quoted
tension and remove th e assembly and seal. under the headin g 'Torqu e Wrench Speci fi ca ti ons' in
8. Remove th e speedometer cab le and driven gea r from thi s Sec ti on.
th e transmi ss ion. 3. Adjust cl utch co ntrol cable as outl ined in 'C lutch' in
9. Remove propell er shaft assembly (Refer ' Rear Sus- this Section .
pension, Rea r Axl es and Propeller Shaft' Secti on of thi s 4. Adjust gea rshift linkag e as outlin ed in th is Sec ti on.
Manual for detail s). In se rt a pl ug in th e end of th e 5. Fill tran smi ss ion to co rr ect level usin g tran smi ssion oil
transmi ss ion extension to prevent oil accum ul ated in to GMH speci fi ca tion HN1 046.
0
......
~--KNOB
I
....&.
en
C')
r-
c
~
C')
BOOT ::I:
SEAL )>
BOOT z
c
~
R IVET - 12 PLAC ES
DI A PH RAGM
:n
)>
z
CJ)
£ SCREW- 3 PLA CES 3:
SECTION A-A u;
CJ)
D IAPHR AGM 0
z
CJ)
RETA IN ER
APPLY A B EAD OF SEALER

HN 1075 ALONG FLANGE AT
HOLE CENTRES TO SEAL
BETWEEN BOOT RET A INER
AND FLOORPAN.
-_zj
& 20 - 25 Nm
Figure 7-14
Transmission Control Assembly Installation Details - MC6 Transmission.
I
I
"
I -~ ~
MA IN WIRING
~;~ ~--
LEAD ASM.
BANK-UP SWITCH ,' HARNESS
[A] \ \ \ ,~_ (lc_~~'")~

,' ((
' ~-«:<~ -' ~~- ----~ ~ '""' """!/ --~11

'·,~;\ ~/
,'
L
IGHTSWITCH ~~Jf'._,\
--r~
BACK -UP
.~ ~ l)( , Z~'i,
_ -:: / )-;;:;--c~' } @__:_~/!6~~(-
I
..... 1 p/ . , .c o' "'-',, " i/
;-/ ~- ~~\ Iy -------~ ~

/-q:---- /~//
/!J IAI
~-·'
/ • ' / l I VIEW
'--~~ ~
,/1,\(·--------
'\, ----- / SILENCER '\' \ ,
WITH MC6
/ ' / -~
'-._ CLI , ' '-. BA CK-UP LIGHT
"" / RETAIN UNDER '\_, / SWITCH
_________ ' / (")

r-
////
c
EX ISTING ATTACH lNG ~
---~~. - -....... -- '-,....::--, (")
PARTS
-:~-
~~)' a'~,~i\c-0 ~A-:ry5"1
-"'
,,
:I:
_.........---~-- 1
,} "' -="'1
)>
z
c
~,'-----~-~ ~::;l_(&/)
v
f((
... '~l-~-__...1 l.f/
~
::c
·~ ,-"'-o.·:~ _:;!) " / )>
~-- --·
z
CJ)
3:
VIEW IAI CJ)
CJ)
WITH M20, M21
0
z
CJ)
0
........
Figure 7-15 .....
I
Back-up Light Switch Installation Details - M20 , M21 and MC6 Transmissions ........
2 PLACES-- WASHER-----,
~
~~~~-r,,
.$>
'
-- ~ -
,
~
~;/';
~ , ~-~
~---=
y ,
r SPACER
(2 PLACES) ON THM 400 ONLY
~
u- -
~-BOLT ~~} REAR ENGINE MOUrJT ASM.
2 PLACES~-- BOLT (THM) j_ \ '!~
~ \ ; I j ($~
. ~~
®''\,'-
i:~·O
I
£
~~
~
- -
' " 1.........--
~~:( ~~
"~/
Jl " REAR CROSS MEMBER ASM .
~
I
WASHER , ',
(2 PLACES) '\. :
(SllJ ~~
SPACER
@I
FOLD DOWN .~ ~l. -
WASHER
(2 PLACES)
CORNER AFTER }if'\
ASSEMBLY----/ ~ ~ WASHER BO LT g, 40-50 Nm
(2 PLACES) (2 PLACES)
_& BOLT -- 34-46 Nm
(2 PLACES)
40 -51 Nm
Figure 7-16
Engine Rear Mounti ng - All VB Models.
MC6 TORQUEMASTER TRANSMISSION 8. Remove the two bolts attac hing the engine rear
mounting to the eng ine rear c rossmember.
Major Service Operations fo r the MC6 transmission are 9. Fold back the lock plates and remove the two engine
cove red in the '4-speed To rque Master Service Manual ', rear crossmember to frame bolts and washers (Refer
pa rt number M37601 with the excep tion of the following:- Fig. 7 -16) remove crossmember.
TRANSMISSION ASSEMBLY 10. Remove the clutch housing lowe r cover.
11 . Lower transmission sufficiently to gain access to the
Removal c lutch housing to engine block attaching bolts .
1. Disconnect battery cab les at battery, disconnec t the 12 . Remove clutch ho using to engine attaching bol ts.
exhaust pipe from the manifold and remove starter 13. Withdraw transmission assembly from engine .
motor assembly. NOTE: Keep the transmission assembly supported so that
2. Remove the transmission control assembly as outlined it will not tilt in relation to the engine until the clutch gear
in this Section. Plug the control lever opening in the spline is clear of the clutch plate. If the transmission is
transmissi on extension to prevent the entry of foreign allowed to 'hang' on the splines, the c lutc h will be dam -
material. aged.
3. Raise vehi cle front and rear and support on jack
stands. Installation
4. Disconnect clutch co ntrol cab le from clutch fork (Refer Installation procedures are the reverse to removal noting
'C lutch' in this Section for con trol cable removal de- the following :- Refer Fig. 7-17 for details.
tai ls). 1. Before installing the tran smission , ca rry out the
5. Disconnec t speedometer cable, TCS switch and primary clutch adjustment as ou tlined in 'C lutch ' in this
back-up ligh t switch electrical cab les. section .
6. Remove prope ll er shaft assembly (Refer 'Rear Sus- 2. Tighten attaching bolts and nuts to th e values quoted
pension, Rear Ax les and Propeller Shaft' Section of this under the heading 'Torque Wren c h Spec ifi ca ti ons' in
manual for details) . Insert a plug in th e end of th e this Section.
transmission extension to prevent oil from dripping 3. Adjust the clutch control ca ble as outlined in 'C lutch'
onto the floor . in this Section.
7. Place a block of wood under the oil pan and support 4. Fill tran smission to correct level using transmi ss ion oil
the we igh t of the eng in e with a lifting jack to GMH spec ification HN1 046.
// ?'
-~
.;;.::----~ -<)\
~
_:;--
------
n
r-
c
BEARING & SLEEVE ASM.-- -t
'-.....
n
:I:
)>
z
c
-t
:0
)>
z
CJ)
& 20-28Nm.
VIEW~ s:::
£ 61-71 Nm.
2 PLACES c;;
CJ)
ill 41-50 Nm. 6
.ffi 8-10 ,6Nm .
z
CJ)
0
I
Figure 7-17 """"'
...L
Installation Details - MCS Transmission. CD
SPECIFICATIONS
Transmission MC6 M20 M21

Number of Forward Speeds 4 4 4
Transmission In first 3.50 3.05 2.54
Ratios In second 2.02 2.19 1.83
In third 1.41 1.1 5 1.38
In fourth 1.00 1.00 1.00
In reverse 3.57 3.05 2.54
Synchromash .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Al l Forward
Shift Lever Location . ... .. .... 0 ••• • 0 • • • • • • • • • • • • • • • • • • • • • • • • • • • • Floor Con sole
Lubricant Capacity - litres . . . . . . . . . . 0 •••• 0 •• •••• 0 ••• MC6 · 1.76 M20 & M21 - 2.0
Type recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 • • • • • • • • • • 0 •••• HN1046
SAE Vi scosi ty Number Summ er . . . . . . . . . . . 0 • 0 • 0 •••• 0 •••• 0 •••• 0 0 •• •• 0 ••• SAE 80-90
Win te r . . . . . . . . . . . . . . 0 ••••• 0 •••••••••• o •••• o • ••• SAE 80-90

Nm
Transmission to Clutch Hou sing Bolts - M20 & M21 . . . . . . . . . . . .. . ... 0 •••• 0 •
41 -47
Clutch Housing to Engin e Bolts - MC6 . ... . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 61 -71
Engine Rear Crossmenber to Frame Bolts ....... ..... ...... . . . . . . . . . . . . 0
40-50
Engine Rear Moun ting to Transmission Extension · M20, M21 , M40 . ...... 0 •••••
34-46
Engine Rear Mounting to Transmi ssion Extension· M41 or MC6 . . . . . . . . . . . . . . . 40-50
Engine Rear Mounting to Crossmember .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-46
Transmission Control A ssembly to Transmission Extension - MC6 .... ... . .... . . 20-25
Gearshift Mounting & Lever Assembl y to Transmission Extension- M20 & M21 .... . 20-29
Starter Motor to Clutch Housing - MC6 ... .. ... . .. 0 •• •••••• •••••••••• 0 • 20-28
CLUTCH AND TRANSMISSIONS 07-2 1
TRIMATIC AUTOMATIC TRANSMISSION

INDEX
GENERAL INFORMATION .............................................. 07-21 SELECTOR CONTROL LEVER ASSEMBLY ............... 07-27
TRANSMISSION CODES ................................................. 07-21 REMOVAL .................................................................. 07-27
TRANSMISSION CASE .................................................... 07-21 INSTALLATION .......................................................... 07-27
TORQUE CONVERTER HOUSING ................................ 07-21 DETENT ACTUATING SWITCH ..................................... 07-27
TRANSMISSION CONTROL SPARK SWITCH ............ 07-21 REMOVAL .................................................................. 07-27
TRANSMISSION OIL COOLER LINES & INSTALLATION .......................................................... 07-27
CONNECTIONS ................................................................. 07-21 ADJUSTMENT ............................................................ 07-27
TORQUE CONVERTER ASSEMBLIES ......................... 07-24 VALVE BODY SERVICE OPERATIONS -
GOVERNOR FILTEA SCREEN ...................................... 07-24 CODE FO AN D KO TRANSMISSIONS ......................... 07-27
SERVO PISTON ................................................................ 07-24 LOW SPEED TIMING VALVE REMOVAL ............ 07-31
BOOST VALVE AND SLEEVE ...................................... 07-24 LOW SPEED TIMING VALVE INSTALLATION ... 07-31
LOW SPEED TIMING VALVE ........................................ 07-24 LINE PRESSURE CHECKS ............................................ 07-31
TRANSFER PLATES ........................................................ 07-24 CHECKING PROCEDURE ....................................... 07-31
VACUUM MODULATOR VALVE & SLEEVE .............. 07-24 MAJOR SERVICE OPERATIONS .................................. 07-32
VACUUM MODULATOR VALVE AN D SLEEVE TRANSMISSION ASSEMBLY ......................................... 07-32
OPERATION ............................................................... 07-25 REMOVAL .................................................................. 07-32
TRANSMISSION SPRING IDENTIFICATION ................ 07-25 INSTALLATION .......................................................... 07-32
TRANSMISSION SHIFT SPEEDS .................................. 07-25 TRANSMISSION SHIFT SPEED CHART ...................... 07-37
MINOR SERVICE OPERATIONS ................................... 07-27 TORQUE WRENCH SPECIFICATIONS ........................ 07-37
BAND ADJUSTMENT CODES FO & KO ..................... 07-27 SPRING IDENTIFICATION CHART ............................... 07-38
MANUAL CONTROL LINKAGE ADJUSTMENT ......... 07-27 SPECIFICATIONS ............................................................. 07-39
INDEXING SELECTOR POINTER .......................... 07-27
NEUTRAL START & BACK-UP SWITCH ..................... 07-27
REMOVAL .................................................................. 07-27
INSTALLATION .......................................................... 07-27
GENERAL INFORMATION
The Trimatic Automatic Transmission is standard equip- hand control ' type transmission case ie. the manual con trol
ment in VB series on BVL with the 3300 L6 Engine and BVX cross shaft extends through the left hand side of the case,
with the 4.2 VB engine. Trimatic is available as a production to suit the floor shift mechanism.
option on BVK models with either the 3300 L6 or 4.2 VB
engines. Transmission range selection is achieved on all TORQUE CONVERTER HOUSING
models through a floor mounted selector lever in a console .
The Selector Indicator in marked P, R, N, D, 2, 1. Code FO (3300 engine) transmissions have a full circle
converter housing. The housing differs from previ ous L6
The Trimatic transmissions in VB Models are series 3
types only in the design of the area whi ch attaches to the
assemblies and generally simi liar to those used with
engine block. VB type converter hou sing s are carried ove r
comparable Holden HZ or Torana UC series engines ex-
unchanged from previous VB models.
cept as noted in the following paragraphs. The series 3
Trimatic Service Manuals Volume 1, P/ N M37B23 and
Volume 2, P/ N M37B24 should be used in conjunction with TRANSMISSION CONTROL SPARK SWITCH
the following information when servicing the Trimatic as -
Code FO (3300 engine) Trimatics do not have a TCS
sembly for VB series .
switch. The opening in the transmission case normally
occ upied by the switch is sealed with a plug .
TRANSMISSION CODES
The transmission identification plate carries the trans- TRANSMISSION OIL COOLER LINES AND
mission serial number and application code. The following
transmission codes are used for VB series Trimatic
CONNECTIONS
transmissions. With the introduction of the cross flow radiator, the
Code Engine transmission oil cooler is located in the right hand radiator
FO ... ..... ............. ... ········································ ... .. 3300 tank, on vehicles with L6 engines and the left hand tank for
............. .... ....... ....... ..................................... ... ...... 4.2 VB . On L6 and VB installations, cooler lines are attached to
KO
the right hand frame with flexible hoses between the
TRANSMISSION CASE transmission and lines. There are different cooler line
connections at the radiator for L6 and VB engines. Refer
Both transmission codes used in VB series have a ' Left Figs. 7-1 B and 7 -1BA for details.
0
.......
I
* DURI NG TIGH TEN IN G OF COO LER PI PE NUTS ,

"'"'
(")
THE COOLER PIPE CON NECTOR S MUST BE HEL D r-
FIR MLY TO PREVENT OVER TIGH TENI NG OF c
ADAPTOR S. -t
(")
:J:
)>
I &
z
COO LER PIP E ADAPTORS c
-t
::c
~~ )>
BEND TAB OVER TO
O I L COOLER OUTLET PIPE A- ~\ ~~ RETAIN PIPE z
en
-
I
/__'
OI LCOO LER I N~ETPIPE Y,/ I~
'I'\ "-------
\~ / /,
,',! '",,\ s:::
(j)
..
en
-~~~ ,): ___ '~ ~ 0
~/" - -- ~ ~-- ~', ~ - z
en
~ ~--- ~ -- 4 oRCONTINU A TIONREF . V IE W 0J
I ,, , )
\) ' #
,-'/(--. ,'/ / / /
I - /____::_·-~~ r------n ~
if~~~,~ - ~
<F.
I
'-....
/" ..__
In ~
-~ ----
I ~--·
ADAPTOR S
HOSE CLAMP
4 PLACES
,&, 12-16Nm
,&. 14 · 19 Nm
Figure 7-18
Transmission Cooler Line Connections - L6 Engines
4 PLACES
WITH M41
& ADAPTOR OIL COOLER INLE T PIPE
n
I
c
-4
n
:I:
)>
z
* DURING TIGHT ENING OF COOL ER 0
& ADAPTOR PIPE NU T S. THE COOLER PIPE
-4
CONN ECTORS M UST BE HELD FIRML Y
TO PREVENT OV ER TIGHT EN ING OF
::c
)>
ADAPTORS.
WITH M40
zCJ)
3:
(j)
CJ)
& 12 - 16Nm. 0
&1 4-19Nm.
z
CJ)
0
.....,
I
Figu re 7- 18A 1\)
Transmission Cooler Li ne Con nections- VS Eng ines (...)
TORQUE CONVERTER ASSEMBLIES

Two different torque converter assemblies are used in VB
series. Code KO transmissions use an 11.3 /4 inch as-
sembly while th e FO code uses a 1 0 inch assembly. The
V8 type converter is attached to the converter drive plate
by three bolts and nuts. Because of the full circle converter
housing , the converter for code FO transmission is
attached to the drive plate with three self locking bolts
engaging nuts welded to the converter lugs.
NOTE: The self locking bolts have a 1 Omm thread.
GOVERNOR FILTEA SCREEN

The governor filter screen is located in a bore in th e
governor hub. Fig. 7-19. The sc reen is a press fit in th e hu b
and should not be removed.
SERVO PISTON
Two different se rvo pistons are used in VB se ries Trimatic.
Refer Fig . 7-20 for identification detai ls.
BOOST VALVE AND SLEEVE

Codes KO and FO use the same type pressure regulator
valve and sleeve. Refer Fig. 7-21 for valve identificati on
details.
LOW SPEED TIMING VALVE

The low speed timing valve train for codes FO and KO
differs from that illustrated in the Trimatic Servi ce Man ual
Volum es 1 and 2 in that the low speed timing cont rol va lve
has been deleted, the co ntrol valve sleeve replaced by a Fi gure 7-19
hollow plug and a revi sed low speed timing valve used . The Governor Filter Screen
eff ect of th ese revisions has been to prevent the operation
of the low speed timing valve from being in fl uenced by
modulator press ure. Low speed timing valve operati on and
th erefore th e orifi c in g of servo release oil is now controll ed
by governor pressure and spring force on ly. (Refer
Fig . 7-22).
TRANSFER PLATES
Transfer plates are identified by th eir part number stamp ed
D I ME NSION "A" CODE KO . . .... 27.99/27.74 mm
in th e area shown in Fig. 7-23. Transfer plat e part numbers DIMENSION " A " CO DE FO 0 0 •••
0 •••••
••••••• 26.4 7/26.21 mm

and application for VB Trimatic transmission are as foll ows.
Transfer Plate P/ N App li ca ti on Figure 7-20
92000425 ... ..... ......... .. . ..... o···o· ·· o·· o··· o·· ······ Code FO Servo Piston Identification Details
9941994 ............................... Code KO
VACUUM MODULATOR VALVE AND

SLEEVE
Vacuum Mod ulator valve and sleeve application for Codes
FO and KO is as foll ows. Refer Fig. 7-24 for valve iden -
tification details.
Valve PIN ............................ .. 2820777
Valve Identification .... One identification band
Sleeve PI N ................................................................. 2820778 Figure 7-21
Sleeve Identification oo ..................... o...... ........... ................. .. Blue Boost Va lve Identification
RETAINING PIN
LOW SPEED TIMING VALVE
Figure 7-22
Low Speed Timing Valve Installation Details Codes FO & KO
PART NUMBER -~
STAM PED IN THIS AREA \:f:T
=_]~
$-' 0
00 0
00 0
40 0
0
0
C)
VACUUM
MODULATOR
Figure 7-23 LINE
Transfer Plate Identificatio n Details.
Figure 7-25
Vacu um Modulator Valve and Sleeve
( ~ VACUUM MODULATOR VALVE AN D SLEEVE

OPERATION
IDENTIFI CATION BANDl Vacuum modulator valve and sleeve operation is the same
IN THIS A REA as described in Volume 1 of the Series 3 Trimatic Trans-
mission Service Manual.
Figure 7-24
Vacuum Modulator Valve Identification Details.
TRANSMISSION SPRING IDENTIFICATION
For details of spring identification, refer to the 'Spring
Identifica tion Chart' at the rear of thi s Section.
TRANSMISSION SHIFT SPEEDS

For details of transmission shift speeds, refer to the
'Transmission Shi ft Speed Chart' at the rea r of thi s section.
0
R IV ET-CO VER & SE LE CT OR ......
I
~/ CONTROL A SM TO BODY 1\)
m
~ ~cOVER
(")
r-
~ APPLY A BEAD OF SEAL ER c
-f
HN-1075 ALONG F L A NG E A T
HO L E CENTRES T O S EAL BE TWEEN (")
COVER & SELECTOR CON T ROL ASM . :I:
)>
z
c
-f
JJ
)>
WASHER , z
en
SPRING WAS HER 3:
en
' ,::; ~
,.. '
0
~~/~:v-'Y
\:-- 4"
CONTROL
ROD -...
A PP LY A BEAD O F SEA L ER
HN- 1075 A LONG F L A NGE z
~_f..
.------.-...· ~
A T HOLE C ENTR ES
en
Ks--
EX T ERNAL -~
=
CONTROL LEVE R
~-,r:;:: L CLE V IS PI N
SEALER
~
\ WA SHER SELECTOR CONTROL

ASM .
LR ET A IN ER
COVER
INS ULA T OR
~@r , r- SA FE TY BOLT
SECTION A-A
WAS. HE~/
1!,,~
~~ LOCKN UT r YOK E
A ~~ L~ ~SH IFTR O D
f~& ~'
EXTERNAL CONTROL LEVER
IM PACT WRENCH
M UST NOT BE USED T URBO HYDRA-MATIC
AT T HIS LOCATION SHIF T LEVER D ETAI LS ffi 11-15Nm
Figure 7-26
Manual Control Linkage Installation - 4.2 & LS with Trimatic & 5.0 Litre with Turbo Hydramatic Transmission.

BAND ADJUSTMENT - CODES FO AND KO INSTALLATION
1. Remo ve oil pan and servo cover, loosen adjusting screw In stallati on procedu res are reverse to removal no ti ng th e
lock nut. foll owing.
2. Using tool 7 AT4 and torque wrench , tighten adjusting 1. Con nect wiring as shown in Fig. 7-28.
screw to 4.5Nm then back off screw six (6) turns for 2. Ind ex selector pointer as described previo usly.
Cod e FO and five (5) turn s for KO transmissions .
3. Tighten lock nut and install servo cover and oil pan .
Refi ll transmission with Dexron II. Au tomatic Trans- SELECTOR CONTROL LEVER ASSEMBLY
mission Flu id.
REMOVAL
MANUAL CONTROL LINKAGE
1. Rem ove th e co nsole as out li ned in th e 'Body, Sheet
ADJUSTMENT
Meta l, Radiator Grille and Bumper Bars' section of thi s
The manual co ntrol linkage should be adj usted as foll ows . Manual.
(Refer Fig . 7-26). 2. Under th e vehicle , rem ove the lower lever from th e
se lec tor assembly after removin g th e attac hing nut.
1. Loosen th e lock sc rew in th e tran smi ssio n co ntrol rod
3. Rem ove th e neutral start and bac k- up light switch.
trunnion .
4. Slide selec tor shaft out of its bore and remove th e
2. Set the se lector lever in th e 'P' position.
se lector co ntrol lever assembly.
3. Move the external co ntrol leve r on th e trans mi ss ion to
the ' Park' posi tion and ti ghten lock sc rew to 18- INSTALLATION
24 Nm .
Instal lation procedures are reve rse to removal. Notin g th e
NOTE: Chec k th e ope rati on of th e neutral start switc h by fo ll owing: -
turning the ignition switc h to th e start positi on. Th e start er
1. Check neutral start and back up switc h operation.
sho uld operate on ly ' P' and 'N' positions . Th e neutral start
swi tch is non adjustab le and shoul d it not perform co r- 2. Index selector pointer as described previou sly.
rectl y, it must be replaced .
4. Check indexing of selecto r poin ter with se lector scale.
If adjustment is necessa ry, proceed as outlined in th e DETENT ACTUATING SWITCH
foll owing paragraph.
Refer Fig . 7-29 for assemb ly details.
INDEXING SELECTOR POINTER
1. Pa rt ially co mpress sides of console cap, then lift ca p REMOVAL
upwards. Turn cap 90 degrees to c lear co ntrol leve r Remove bolt and nut attac hin g detent actu atin g switc h to
handle through openin g in co nso le cap. mounting brac ket and discon nect electri c wirin g.
2. Locate gea rshi ft co ntrol leve r in th e Neutral pos iti on
(3 rd rearwa rd pos iti on). INSTALLATION
3. Ensure that th e poin ter embossed on th e co ntrol leve r 1. Adjust throttl e con trol ca ble as outlin ed in th e 'Engine
opening cover is pointi ng direc tl y at 'N'. If necessa ry , - Fuel ' section of thi s Manual.
adjust gearshi ft indi ca tor scale as follows . 2. Depress accelerator control pedal to full throttl e
4. Lift fron t of indicator scale and loca te ' N' on sca le to pos iti on and install switch by in sertin g switch mounting
co inc ide with pointer on opening cove r. bolt into one of the three switch mounting holes that
is nea rest to the accelerator pedal lever. Release
NOTE: The sid es of th e indicator sca le are lo cated in a
acce lerator pedal and install wa shers and attac hin g
lipped recess of the co nso le (See sec ti on B- B, Fig. 7-2 7).
nut to bolt. Install electric wiring .
A serrated secti on under the front end of th e indicator scale
indexes with correspondi ng se rrations mou lded into th e
console (See sect ion A-A Fig. 7 -27) and is retained in
ADJUSTMENT
position by th e console cap. 1. After instal ling the sw itc h as described above, press
th e switch plunger as far forwa rd as possib le. Thi s
5. In stall console cap .
presets th e switch for adjustment. The switch will
adj ust itself with the fi rst wide open throttl e ap pli ca ti on
of th e accelerato r pedal.
NEUTRAL START AND BACK-UP SWITCH
REMOVAL
1. Remove co nso le ca p (Refer previous head ing). VALVE BODY SERVICE OPERATIONS-
2. Remove co nso le (Refer ' Body , Shee t Metal , Radiator CODE FO AND KO TRANSMISSIONS
Grille and Bumper Bars' Secti on of thi s Manual. Serv ice operations for valve bodies of co de FO and KO
3. Di sco nn ect wi ring for neutral start and back up li gh t tran smi ss ion s are esse ntially th e sa me as outl ined in
switch at co nnec to rs (Refer Fig. 7-28 for detail s). Volume 2 of the Se ri es 3 Trimati c Transmission Servi ce
4. Remove th e two sc rews attaching th e neut ral start and Manua l except where th e low speed timing va lve train is
back- up switc h and remove switc h. co nce rn ed . Refer Fig . 7-22 for detail s.
0
"""'
I
1\)
co
(')
CONSOLE CAP r-
=i
(')
:I:
)>
COVER CONTROL z
LEVER OPENING
SECTION A-A c
-1
:tl
)>
z
CJ)
WITH GEAR
SHIFT LEVER IN NEUTRAL, RETAIN SCALE AS s:
ALIGN ' N ' ON SCALE WITH
INDICATOR ARROW ON COVER
SHOWN. u;
BEFORE RETAINING SCALE
CJ)
0
z
CJ)
SECTION B-B
SECTION C-C
(4 PLACES)
Figure 7-27
Transmission Selector Indicator - Trimatic and Turbo Hydramatic Transmissions.
VIOLET LEAD
YELLOW PARK
LIGHT GREEN LEAD
BRAKE LEAD ~
PINK LEAD
MAIN WIRING HARNESS
(_1
_~------ -----
I
I
...... \
___/
/
---------
LAMP
SUPPORT
I "----
\ /
"'/~'
(')
,\ r-
c
\\ ) ~ ciJ:
\ / '\
~' ~'" )>
z
SILENCER~~~'," '~""
LT. GREEN LEAD '
c
-f
::c
)>
' ~ "'- z
~ CJ)
3:
Ci5
CJ)
0
zCJ)
0
I
Figure 7-28
""""
1\)
(0
Neutral Sta rt and Back-up Switch Wiring Installation - Tri matic and Turbo Hydramatic Transmissions.
0
.......
I
w
0
n
r-
c
-4
LDNUT--- n
SWITCH INSTAL L A TION PROCEDURE : :I:
AFTER THROTTLE CONTROL HAS BEEN
ADJU ST ED DEP RESS ACCELERATOR
)>
CONTR OL PEDA L TO FULL THROTTLE . z
SWITCH MOUN TING BOLT SHOULD BE c
INSERT ED IN T O ONE OF THE
DETENT SWITC H A SSEMBLY_\ THREE SW ITC H MOUNTING -4
HOLES THAT IS NEAREST TO THE J'l
ACCEL LERA TOR PEDAL LEVER .- )>
RELEASE ACC ELERA T OR PEDAL
AND IN STALL THE SWITCH .
z
(/)
s:::
u;
(/)
~VIEwiAI 0
I
I I
z
ACC ELERATOR
PEDAL BRACKET
\ ., '\ ..
(/)
)
' '
:I
ADJU STMENT PRO CEDURE :

A FTER INSTALLING SW ITCH AS DESCRIBE D PRESS
SWIT CH PLUNGER AS FAR FORWARD A S POSS I B L E.
THI S PRESETS SWITCH FOR ADJUSMENT.
II~Jr1~
1:1, 1 1 11~ :
SWIT CH WILL A DJUST ITSELF WITH FIR ST WIDE !I .Jil
OPE N TH ROTTLE A PPLICAT ION OF A CCE LERATOR PEDAL.
I' li /i :
w_l!~
i/11
_f,\ 8 - 10.6Nm
Figure 7-29
Detent Actuating Switch Assembly Details.
LOW SPEED TIMING VALVE REMOVA L of th e possibility of th e vehi c le inadvert ently moving with
1. Remove th e high speed downshift timin g valve re- th e dang er of injury to personnel or damage to property.
tai ning pin , sprin g and valve. Check number 3 sho uld be conducted as quickly as
2. Remove th e retaining pin from th e low speed timing practi ca ble. Do not hold 1200 eng in e rpm for longer th an
va lve plug and remove th e plug . ten ( 1 0) seco nds si nce fluid in the co nverter may overh ea t
3. Remove the low speed timing valve and spring. and cause damage to th e converter housing oil sea l.
Th e purpose of chec k number 1 is to determin e minimum
LOW SPEED TIMING VALVE INSTALLATI ON line press ure at a given engin e speed when the regulator
1. In stall th e low speed timin g valve sp rin g and valve into valve and spring are the co ntrollin g factors . Check number
th e valve body bore. 2 introd uces the boost va lve to check the boost ci rcuit and
2. In stall th e low speed timing va lve plug into th e valve chec k number 3 sim ulates full throttl e operation in '0'
body. Retain th e plug with th e original or same type rang e by having full modulator pressure operating on th e
pin . Th e use of thi s type pin is required to prevent loss boost valve to check th e mod ul ator circui t at a given engine
of modulator pressu re. Refer Fig. 7-22 for co rrec t speed .
location of the plug and pin.
3. In stall th e high speed downshift timing valve, spring CHECKING PROCEDURE
and retaining pin . 1. Connect the pressure gauge into the line pressure
tapping in the left hand side of th e tran smi ss in case.
2. Install a tachome ter to th e engin e. Set tachometer to
LINE PRESSURE CHECKS the 5000 rpm scale.
Line pressure should be c hecked with an accurate pres - 3. Thoroughly warm transmi ss ion and check transmiss-
sure gauge (Too l No. HM1844 or similar) co nnected into ion fluid level.
the press ure tapping in the left hand side of the trans- 4. Conduct checks 1, 2 and 3 and compare th e readings
mission case. Checks must be mad e with the transmission wi th the valu es shown in the 'Line Pressure
at stabilized operating temperature after first ensuring that Specification Chart'.
th e fluid leve l is co rrect. NOTE: When the three c hecks have been comp leted, let the
NOTE: Stabilized opera ting temperature is not attain ed engine idle in ' 0 ' range and note the idle lin e pressure. If
until th e transmi ss ion fluid has reached 80 degrees to th is reading is no more than 34.5 kPa below the read in g
88 degrees C. Thi s temperature is not ac hieved until the obtained in check No . 1 th e pressure can be cons id ered
vehi cle has cove red at least 16 km of stop/start operation . sati sfactory. If th e reading is more than 34.5 kPa be low that
Three pressure checks are used for diagnosis and ope r- obtained in check No. 1 it indicates a jammed regulator
ati onal checks of the Trimatic transmission . Checks 1 q.nd valve or poor pump output due to excessive gear clea ran ce
2 are mad e with th e vacuum modulator pipe connected to etc. and/or excessive internal leakage in the transmission .
th e inl et manifold and an engine vacuum reading higher Any of these conditions will require further investigation.
than 16 inches Hg. This is necessary to ensure that the NOTE: When assessing the results of Check No . 2, a sit-
modulator is having no eff ec t on lin e pressure, and is best uation may by enco untered where the line pressu re ob-
ac hi eved with th e vehicle coas ting. Check number 3 cann ot tained durin g coast ope rati on is satisfactory, but the line
be perform ed with th e vehicle moving because of th e effect pressure in '2' and ' 1' ranges with th e engi ne idling is
of gove rn or pressure on th e mod ul ato r va lve whi ch red uces signifi ca ntly below th e value obtain ed during th e chec k on
mod ulator press ure and lin e press ure. Chec k number 3 th e road. Thi s co nditi on is due to the lower pump speed at
must therefore be ca rried out with th e vehicle stati onary engine idle co upled with so me possible fluid loss in the
und er a 'li ght stall ' co nditi on at 1200 engin e rpm . third clutch ci rcuit.
NOTE: Si nce check number 3 involves a partial stall test, As a guide, if the lin e press ure in '2' and '1' at engine idle
it must be ca rri ed out with du e rega rd to safety. This chec k with the transmission hot does not fall below the value
should be cond ucted as part of th e road test with the obtain ed in '0 ' rang e during Check No. 1, then the oil pump
vehicle in th e open . Even a partial stall test can be body bushing can be considered serviceable and shou ld
potentially dangerous if conduc ted in a workshop because not be repla ced.
LINE PRESSURE SPECIFICATION CHART
TRANSMISSION CODES
FO KO
3300 4 .2
CH ECK No . 1 -Line Pressure in D Range (V ac uum Modu lator Pipe Connected) kPa kPa
V ehi cle coast ing between 55 -50km / h 324- 366 393-434
CH ECK No . 2 - Line Press ure in 2 & 1 Ranges (Vacuum Modulator Pipe Connected) 531 - 614 648 - 730
V ehicl e Coasting between 40-30km/ h
CH EC K N o . 3 * - Line Press ure in D Ran ge ( V acuum Modulator Pipe Di sconn ected) 903 - 978 972-1068
1200 R.P .M . engin e speed - foot and parking brake appl ied
* During Check No.3 with the vacuum modulator pipe disconnected , th e manifold connector must be applied to
preve nt an excessive air l ea k into the manifold .

TRANSMISSION ASSEMBLY 1B. Position a suitable support under the engine oil pan to
take the weight of the engine once the transmission is
removed.
REMOVAL
19. Remove the remaining converter housing to engine
1. Disconnect both cables from the battery.
attaching bolts and remove transmission assembly.
2 Disconnect the starter motor cables.
20. Install converter holding tool number 7 A27 to prevent
3. Remove the starter motor attaching bolts. Remove converter becoming dislodged.
starter motor. Remove the exhaust pipe to manifold
attaching nuts, remove pipe(s) from manifold(s).
4. Raise the vehicle and support it on jack stands front
and rear.
INSTALLATION
NOTE: A clearance of approximately 22 inches between
NOTE: If the transmission has been removed and over-
the vehicle underbody and the workshop floor is required
to remove the transmission from beneath the vehicle. hauled because of the presence of foreign material such
as grit or metal particles, or if it is suspected that foreign
matter has entered the torque converter, it will be neces-
CAUTION: After a long run, the transmission fluid will be hot
sary to flush out the torque converter, cooler and con-
enough to cause serious burns, therefore suitable pre-
necting pipes. For details, refer Page 54, Volume 2 of the
cautions must be taken when removing the transmission.
Series 3 Trimatic Service Manual.
5. Remove the speedometer cable retainer attaching bolt,
withdraw speedometer cable from extension. Install a Installation procedure is the reverse of removal, however,
suitable plug to prevent the entry of dirt or foreign particular attention should be paid to the following points.
matter into th e extension. Refer Figs. 7-30, 7-31, 7-32 and 7-33 for transmission
installation details.
6. Disconnect the oil coole r hoses from the transmission.
To prevent dirt entry, plug both hoses and transmission
connectors. 1. Before offering the transmission assembly up to the
7. Disconnect detent switch cable from solenoid con- engine, ensure that the front face of the converter
nector, and TCS switch cable from switch, if fitted. housing and its mating face on the engine are clean
B. Disconnect vacuum pipe from modulator. and free from burrs. Also that the converter drive plate
to crankshaft attaching bolts are correctly tightened.
9. Remove the converter housing lower cover attaching
bolts. Remove cover. Mark drive plate and converter 2. Ensure that the transmission locating dowels com-
to ensure correct positioning during installation. pletely enter the holes in the converter housing.
10. Remove the converter drive plate to torque conve rter 3. Install the converter housing to engine bolts and
attaching parts. tighten bolts evenly to 61-70 Nm torque on L6 engines ,
and 40-54 Nm torque on VB engines.
NOTE: On the 4.2 engine, the converter is attached to the
drive plate by three nuts and bolts. The converter for L6 4. Prior to installing converter to drive plate attaching
engines is attached to the drive plate with three self locking parts, ensure that the markings made at transmission
bolts engaging weld nuts on the converter lugs. The self removal are correctly aligned.
locking bolts are 1 0 mm. NOTE: Converters have a strip of blue paint to indicate the
11. Remove propeller shaft assembly refer 'Rea r Sus- 'light' side of the assembly. If a new converter is fitted or
pension, Rear Axles and Driveline' Section of this the mark was not made during tran smission removal, it is
Manual for details. Insert a sui tabl e plug in th e 2nd of important to index this blue balance mark with the cor-
the extension to prevent fluid loss from th e tran s- respondence blue mark on the converter drive plate to
mission. main tain balance of the crankshaft and converter.
12. Disconnect the manual control rod from the external 5. Install the drive plate to converter attaching parts.
control lever at the transmission. NOTE: On the 4.2 engine, the converter is attached to the
13. Support the transmission assembly on a suitable dri ve plate by three nuts and bolts. The converter for L6
cradle and secure with chain. Owing to the weight of engines is attached to the drive plate with three self locking
the assembly it is not recommended that removal or bolts engaging weld nuts on the converter lugs. The self
installation be undertaken without the aid of a cradle. locking bolts are 1 Omm.
14. Remove the engine rear mounting to engine rear cross 6. On L6 engines, torque self locking bolts to 45-50 Nm.
member attaching bolts. On 4.2 engines torque bolts to 40-4B Nm.
15. Fold back the lock plates and remove the two engine 7. Adjust the manual control linkage and check neutral
rear cross member to frame bolts and washers (Refer start switch as outlined in 'Minor Service Operations' ,
Fig. 7-16). Remove rear cross member. in this Section.
16 . Lower the transmission sufficiently to gain access to B. Adjust the detent actuating switch as outlined in 'Minor
the co nverter housing to engine attaching bolts. On VB Service Operations' in this section.
models ensure the distributor cap is not damaged as 9. Refill the transmission with 'DEXRON II' automatic
the engine is lowered. transmission fluid as outlined in 'Maintenance Section'
17. Remove the converter housing to engine attaching bolt of Volume 2 of the Series 3 Trimatic Service Manual.
holding the fill er tubP and vacuum line. Before re- 1 0. Test the transmission oil pressure as detailed under
moving the filler tube, ensure the area about the tube the heading 'Line Pressure Checks' in this Section and
is clean. Use a suitable plug to prevent entry of dirt into road test the vehicle to ensure that the transmission
the transmission. operates correctly.
~r r-"-
'
'-._ ) J;j--"-.':"
•·_. '"i
~"ij"~
~ -<~:'-
~
(l
')'1'
',j\\, viii~'
~
• "' ,......____
_/ / '------,,
_' .
I , n' '
I I
) J. .
)0 I
·.
,",
•<- ~
~ ~} ~~
I r" ") ','' "':; '-Z......
( JI .7 1 ~ 1o1
'~
\ ('
\~ - j- -- ' ) l
' ~ ~ ~/ I/ I (
~ ' I j' --- ~; // ,,

~ ~ ~p ~ ~ ' /- .:~~~~-~
~;"~~1
'
~<~_}' -w~
~
/,0
J T"' FLEX t.
I
' -......
-
"'-- //
;I( \'
-~
\
\" ~ '--- PLATE & MATCH BLUE PAINT BALANCE MARK
·----.:_.__=-· / ~-~
c' ~\ \~'~:!.f... TO ON CONVERTER WITH BLUE PAINT
---
~
-_,
~ CONVERTER BALANCE MARK ON DRIVE PLATE.
v ~ BOLTS (AJ
'~( -
,_ ' ' VIEW
<."<2J: ~ CONVERT ER HOUSING
'-1 ~ BOLTS J:o.
('! ~~ (6 PLACES) ffi
; ~~
- S{r',
/
1 0-
m l
o;,' ,~
~~ !'-.
APPLy SEALING PUTTY

HN1351 OVER AREA
I n
SHOWN ~ TO FRONT I
c
FACE OF CONVERTER
HOUSING COVER I /~ \ -t
n
REMOVE EXCESS
SEALER AFTER
'"\ :I:
\~
ASSEMBLY .
;\ -~ )>
z
'' @'~~ " <( c
_--2 f
-t
::0
@? --- Vl :~rm )>
z
CJ)
s:::
(j)
~
i
40-48Nm
40-54 Nm 0
8,5-12Nm z
CJ)
5,0- 7,0 Nm
0
.........
I
Figure 7-30 cu
Transmission Installation Details - 4.2 Engine. cu
LUBRICATE RUBBER SEAL ON TRANS

OIL LEVEL INDICATOR WITH HN 1198
TYPE 1 PROIR TO ASSEMBLY
VIEW [QJ
,& 40 - 54 Nm
Figure 7-31
Filler Tube Installation Details - 4.2 Engine.
,\ MATCH BLUE PAINT BALAN C E MARK ON -
·'-.:--
'~'
I
CONVERTER WITH BLUE PAINT BALANC E
MARK ON DRIVE PLATE
I ffi
,.,_
/-!2)''-.l;t) -,
''--- --- -. ' . ' ---
,_
/ .,>.
&,
~r-) """ OILFIL

~U
~ - vrewlAJ
' 0
£ .......
I
(A)
LOWER COV ER U1
0
r-
c
~
:I:
APPLY SEALING PUTTY HN - 1351 ON THE )>
OUTSIDE OF CONVERT ER HOUSING COVER
OVER AREA SHOWN THUS 111/ll///1!1/111!1!11/1 z
REMOVE EXCESS SEALER A FTER ASSEMBLY c
I -t
::0
I )>
"·~ z
en
£ 8 - 10,6N m
s:::
£ 20 - 28 Nm c;;
ffi 45 - 50Nm en
£ 60 - 71 Nm 6
[6 40 - 51 Nm z
en
Figure 7-32
Transmission Installation Details - L6 Engines.
0......,
I
~
(,.)
0)
0
(")
r-
c
/l ~ -4
A1
<
' I I (")
(J 2.,-;_~~~ --~ 'i :I:
\to )>
.. ( r-J" -/
z
fi; · -~ -~, ~rr·__.;·= . !(.
c
IY:;j;/"' '1~ -11l ~~ ~ ~
== :
, -4
MODULATOR PIPE MUST BE IN POSITIVE ,'If ./" . -~
:,·-' /}\ \ .~
"'~
_,.J.
::0
)>
CONTACT WITH CONVERTER ;I z
\~""'.- ~ , -\-~)A\~~r~-
~· /~ ''.'<.I~
HOUSING /,'/ \ ,\ \ en
s::
//\""'--:J ~- c-~~ '-"" en
~~.
y \ -
\ /. ~~ /6, , -~@;- · en
' ~--~
I / I fi:.'/,,
.J~y
0
-7 ''\\'\~'· \ ..._,·.J. z
~~, -,\il \\I /'-
f({)/ ~
en
·.·'-;::: '\~~
//~ I}\ _.. .y :,, r(l~
~'~~ -~~~ _/: _r ~ l\'f l
\
-- --
---
/ ~
~
J--, ____...--
r
ASSEMBLE SEAL
INTO GROOVE
0 COAT WITH HN- 1198 TYPE)

~
cj_
L-1- .
'~
I
-r'h
Ill
- L
~
~ .
lr
CIJ./
- . -- '//
~ (- /.~
~ ~i? ·.·
u
(!) LUBRICATE RUBBER SEAL ON TRANSM .
OIL LEVER INDICATOR WITH HN 1198
TYPE 1, PRIOR TO ASSEMBLY
Figure 7-33
Filler Tube Installation Details - L6 Engines.
TRANSMISSION SHIFT SPEED CHART
UPSHIF TS km/h - CODE FO
CLOSED THROTTLE FULL THROTTLE
1 -2 2- 3 1- 2 2-3
All Tyre Sizes 19 26 67 104
DOWNSHIFTS km /h-C ODE FO
CLOSED THROTTLE FULL THROTTLE PART THROTTLE
2- 1 3- 2 3 - 2 2- 1 3 - 2(Available Up To*)
All Tyre Sizes 15 22 92 53 69
UPSHIFTS km / h- CODE KO
CLOSED THROTTLE FULL THROTTLE
1- 2 2- 3 1- 2 2-3
All Tyre Sizes 21 30 75 117
DOWNSHIFTS km / h- CODE KO
CLOSED THROTTLE FULL THROTTLE PART THROTTLE
2- 1 3- 2 3-2 2- 1 3- 2 (Available Up To *)
All Tyre Sizes 15 24 102 58 67
* WI TH DETENT SW ITCH D ISCONNECTED.

Nm
Shift Control Rod Trunnion Locking Screw .............. 18-24
Drive Plate to Conv. Bolts & Nuts-4.2 engine . ... 40-48
Drive Plate to Conv. Self Locking Bolts -
L6 Engines .................. .... ..... ..... .............................•........ 45-50
Converte r Housing to Engine Bolts -L6 eng in es ...... 6 1-7 0
Conve rt er Housin g to Engine Bolts-4.2 Engines ..... 40-54
Transmission External Control Lever Nut .................. 11-15
Engine Rear Mount. to Trans. Extension Bolts ........ 34-46
Engine Rear Cross Member to Frame Bolts .... ..... 40-50
Engine Rear Crossmembe r to Rea r Mounting ... ...... 34-46
TRIMATIC TRANSMISSION SPRING IDENTIFICATION CHART
FREE AP PLI CAT I ON

SPRING COLOUR LENGTH TOTAL O.D . CO D E CODE SPR IN G
DESCRIPTION IDENTIFICATION APPRO X . COILS mm FO KO PAR T NO.
mm NOMINAL 3300 4.2
3- 2 Cont ro l V alve Y ell ow 54.6 1 15 13.2 1 X 994203 3

Red 51.6 15 13. 21 X 9942031
1- 2 Accumul ator Valve Not Not

Use d Used
Low Speed Downshift Red 45 .72 13.5 10.31 X 525858 4

Valve Orange 41 13 .5 10.31 X 2817224
High Speed Downshift Grey 35.56 13.5 10.54 X 5258580

Timing V alve Purpl e 35.56 13. 5 10.3 1 X 28 16882
Detent Press ure Pink 40.64 11 .5 12 .04 X X 5258582

Regul ator Valve
1- 2 Shift Valve Not No t

Used Used
1- 2 Cont rol V alve None 40. 64 10 14.22 X X 99420 10
2· ·3 Cont rol Valve N one 40.64 10 14.22 X X 99420 10
2· 3 Sh ift V alve N ot N ot
Used Used
Ma n. Low & Rev. Light Green 38 .1 11 .5 10.31 X X 5258547

Control Valves
Pressure Regulator No ne 60.96 12 19.3 X 28 10499

Valve White 69.85 12. 75 19.61 X 5258 166
Dete nt Valve Dark Green 35.56 13 .5 10.3 1 X X 9929681
Accumul ato r Pi ston Light Gree n 48 .26 5.5 3 1.68 X X 525856 3
Gov. Secondary Dark Gree n 38.10 11.5 10.31 X X 9944999
Servo Pi ston Release N one 55.88 5 47 X X 5258572
Servo Piston Cushion Orange 26.16 3 .8 25.4 X 5258568

Red 25.4 4 30. 5 X 5258564
SPECIFICATIONS
TRANSMISSION CODE FO KO
AND ENGINE 3300 4 .2
Selector Lever
Location . . . ... . . . . . . . . . . . . . . . . . .. . ..... .. .. . Floor Floor
Seq uence of Sh ift Positions . . . . . . . . . . . . . . . . . . . . . . . . . . "P" (Park) , " R" (R everse ), "N " (N eutral), "D " (D ri ve)
" 2" (Intermediate ), " 1" (Low Ran ge) .
Torque Converter A sse mbly
Met hod of Atta chmen t to Drive Pl ate .. . . .. .. . . . .. . .. . Weld Nut & Bo lt Nu t & Bol t
Identification Letter (Printed Yell ow on Front Face

of Converter) .. . .. . . . ... .. . .. . . ... .. . . ... .. . . . . . H B
Stall Ratio : 1 . . .... . . .. .. .. ..... ..... .. . . ..... . 2.4 2.2

Diameter (N omina l ) mm .. .. . . .... ... . . . . . . . . . . . . . . . 254 298
Speedo Drive Gear

No. of T eeth . . . . . . . . . ... .. ... . . . . . . . . . . ... . .. . 8 9
Colour .. . . . . . . . .. .. . . . . . .. . . . . .. .. .. ..... .. . Natural Wh ite Blue
Gear Ratios
First . . . . . . . . . . .... . . . ..... . . . . . . . . . . .. . . . . . 2.31 : 1 2.31 : 1
Second .. . ..... .. . . . . . . . . . . . . . . . . . . ... . .... . 1.46 : 1 1.46 : 1
Third .... . .... .. . . . . . . . . . . . . . . . . . . . .... . . . . 1.00 : 1 1.00 : 1
Reverse . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . 1.85 : 1 1.85 : 1
Torqu e Multiplication
Max imum Overall Ratio in 1st : 1 5.54 5.08
Lubricant
Type ..... . . . ... .. .. . . . . . . . . . . . . . . . . . ... .. . " DEXRON II " Autom atic T ransmissi on Flu id
Capacity Litres - Dry (Including Converter) . .. . . . .. . . .. . 6.1 8.7
Refill . . .. . .... . . .. . . . .. .. .. . . . . . . . .. .. . . .... . 1. 7 1. 7
Flu id Level Indi cato r (Di pstick)

Length (From Top of Cap t o End of Ind icator) mm ...... . . 588 679.45
CLUTCHES
Reverse
Type . . . . . . . . ... . . .... . ..... .... ... . . .. · · · · · · · Multi ple Wet Disc
Drive Pl ates
Description .. . .... .. . . . . . . .. . . .. . . .. . .. . . .. . . Friction Facing on Stee l Plate
Num ber . . . . . . . ... . .. .. .. ... ... . . .. .. . . .. . . . . 4 5
Reaction Pl ates
Descri ption ...... .. .. .. . . ..... ... . . . . . . . . . . . . Stee l Steel
Number . . . . . . ... . .... .. . . . . . . .. . .. ... . .. ... . 5 6
Piston
Length mm 36.09 / 35.99 31 .50/ 31 .39
Cushion Pl ate Used .. . . .. .. ... . . . .. .. .. . ..... ... . . Y es Yes

SPECIFICATIONS (Cont'd)
TRA NSMISSION CODE FO KO

AND EN G IN E 3300 4 .2
CLUT CHE S (Cont'd . )

Second
Type . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mult ip le Wet Disc
Drive Plates
Descri ption . . . . . . . . . . . . . . . . . . . ... . . . . . . . . ... . F riction F ac ing on Steel Pl ate
Number .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6
Driven Plates
Description . . . . . . .. .. .. ... . . . . . . . . . . . . . . . . . . . Steel Steel
* Nu mber .. . . . . . . . . .. . ... . . . . . . . . . .. . . . . . . . . . . 6 7
Cush io n Plate Used . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . Yes Yes
* Note: Some Transmissio ns have one add itio n al Stee l Pl ate.
Spacer
Length mm 40.34 /40.23 35.74 / 35.64
Second Clutch S pacers can also be identified by t he last digit of the Part Number on the Spacer. Spacer and Part
Nu m b er application as follo ws:
SPACER NO. APPL ICATION

52 58285 Code FO
2820681 Code KO
Third
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mul tiple Wet Disc
Drive Pl ates
Desc ript ion . . . . . . . . ... . . . . . . . . . . . . . .. ... . ... . Friction Facing on Steel Pl ate
Number ... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 4 4
Driven Pl ates
Description . . . . . .. .. . . . . . . . . . . . . . . . . . .. .. ... . Stee l Steel
Num ber . . .. . . . . . . . . . . ... . . . . . .. . . . . . . .. . . . . . 5 5
Piston
Length mm 17.27 / 17.1 7 17.27/12.17
Cush ion Pl ate Used ... . . . . . . . . . . . . . . . . . . . . . . . . . .. . Yes Yes
O ne Way Clutch
Ty pe .. . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . ... .. . Sprag Sprag
Fu nct io n .. .. . . . . . . . . .. . . . . . . . . . . . . . .. ... . .. . Connects Input to Gear Set in First Gea r Drive,
Over-r uns or by-passed in other conditions.
TURBO HVDRAMATIC 400 AUTOMATIC TRANSMISSION

INDEX
GENERAL INFORMATION .............................................. 07-41 TRANSMISSION SPRING IDENTIFICATION ................ 07-42
TRANSMISSION CODE ................................................... 07-41 MAJOR SERVICE OPERATIONS .................................. 07-42
TRANSMISSION COOLER LINES & TRANSMISSION ASSEMBLY ......................................... 07-42
CONNECTIONS ................................................................. 07-41 REMOVAL .................................................................. 07-42
TORQUE CONVERTER ................................................... 07-41 INSTALLATION .......................................................... 07-43
MINOR SERVICE OPERATIONS ................................... 07-42 TORQUE WRENCH SPECIFICATIONS ........................ 07-43
MANUAL CONTROL LINKAGE ADJUSTMENT ......... 07-42 SPRING IDENTIFICATION CHART ............................... 07-45
TRANSMISSION CHECKING & DIAGNOSIS ............... 07-42 SPECIFICATIONS ............................................................. 07-46
TRANSMISSION SHIFT SPEEDS .................................. 07-42
GENERAL INFORMATION
The Turbo Hydramatic 400 is offered as th e automati c ramati c Transmi ss ions have a fo ur digit se ri al number
transmission option whenever the 5 li tre VB eng ine option prefi xed by th e code 'EK ' and th e last two num erals of th e
is exercised. Turbo Hydramatic is not avai lable with any transmi ss ion model year eg. 78-EK-1234.
other engine in VB series.
Transmission range selection is achieved through a floor
mounted selector lever in a console on all models. The TRANSMISSION COOLER LINES AND
selector indicator is marked P.R.N.D.2.1 . CONNECTIONS
Service operations for the THM400 are covered in the Cooler lines are attached to the right hand frame with
'Turbo Hydramatic 400 Automatic Transmission Service flexible hoses between the transmission and lines. Re fer
Manual ', Part Number M381 07. This manual should be Fig. 7-18A in the 'Trimatic Transmission' Secti on of thi s
used for re ference whenever diagnosis, major and minor Manual for details.
service operations are under taken on THM-400 assem-
blies.
TORQUE CONVERTER
TRANSMISSION CODE
The torqu e co nvert er is attached to th e converter drive
The transmission identification plate carries the trans- plate by three self loc king bolts engag ing nuts welded to
mission serial number and application code. Turbo Hyd- th e convert er cove r.

Min or Se rvi ce operation s on th e THM -400 transmi ss ion NOTE : Check th e operati on of th e neutral start swit ch by
assembly are cove red in detail in th e 'Min or Service Op - turning the ign iti on to th e start positi on. Th e start er should
erati ons' secti on of th e Turbo Hydramati c 400 Tran s- ope rat e only in th e 'P' and 'N' po siti ons. The neutral start
miss ion Se rvi ce Manual PI N M381 07. Th e following switc h is non ad justab le and shoul d it not perform co r-
paragrap hs co ver min or servi ce operati ons not covered in rec tl y, it must be rep laced .
the THM -400 manual. 5. Chec k ind ex in g of se lector pointer with selec tor scale.
Th e foll owing minor se rvi ce operatio ns are common to bo th If adjustmen t is nec essa ry, proceed as outlin ed und er
Turbo Hydramatic and Trimat ic Tran smission s. the heading 'Ind exi ng Se lector Po inter' in th e 'Trimati c
Ind ex in g Se lector Poi nter Tran smi ss ion ' G roup in thi s Section .
Neutral Start and Bac k-up Switch - Removal and In -
stallati on
Selector Con tro l Lever - Removal and Install ation
Detent actuating Switch- Removal, Installati on, Ad- TRANSMISSION CHECKING AND
justment. DIAGNOSIS
For detai ls, refer to th e app ropriate head ings in th e 'Tri- Refer to th e 'Checking and Diag nos is' secti on of th e Turbo
mati c Tran smission ' Group of thi s Secti on. Hydramati c 400 Automatic Tran smi ss ion Se rvi ce Man ual
for details of the above operati ons .
MANUAL CONTROL LINKAGE
ADJUSTMENT
Th e manual co ntrol linkage should be adjusted as foll ows.
(Refer Fig . 7-26 , in the 'Trimati c Tran smi ss ion ' Group in TRANSMISSION SHIFT SPEEDS
thi s Section for iden tifi ca ti on of parts). For details of tran smi ss ion shift speeds refer to th e 'S hift
1. Loosen th e tran smissio n co ntrol rod to yoke nut. Speed Chart ' in 'Speci fi ca ti ons' at th e rea r of thi s Secti on.
2. Un clip safety bol t from the yo ke and remove sa fety
bo lt.
3. Set th e selec tor lever in the 'P' position .
4. Move th e externa l co ntrol lever on th e trans mi ss ion to TRANSMISSION SPRING IDENTIFICATION
th e ' Park' position and adj ust th e yoke on th e control
rod so th at th e sa fety bo lt fre ely en ters th e holes in th e For detail s of spring iden tifi ca ti on, refer to th e 'S pring
yoke and control leve r. Clip sa fety bol t to yoke . Id entificati on Chart ' at the rea r of thi s Secti on.

TRANSMISSION ASSEMBLY
8. Disconn ec t vac uum pip e from mod ulator.
REMOVAL 9. Rem ove the co nverter housin g lower cove r attac hin g
bolts. Remove co ver. Mark drive plate and co nvert er
1. Disconnect both cab les from th e battery.
to ensure co rrect pos iti on in g d uring install ati on .
2. Disconnect the starter motor cables .
1 0. Remove the co nverter drive pl ate to torqu e co nverter
3. Remove the sta rter motor attac hing bol ts. Remove attach in g bolts.
starter motor. Remove th e ex haust pipe to manifold
11 . Remove propell er shaft assemb ly. (Refer ' Rea r Sus-
attac hing nuts, remove pipes from manifolds.
pen sion , Rear Axles and Drivelin e' secti on of thi s
4. Rai se th e vehicle and sup port it on ja ck stand s fron t Manual for detail s). In se rt a suitabl e plug in th e end of
and rea r. the exten sion to prevent fluid loss from th e trans-
NOTE: A clearance of approximately 22 inches between mi ss ion.
th e vehi cle und erb ody and th e workshop fl oo r is required 12. Di sco nn ect the manual co ntrol rod from the extern al
to remove th e transmi ss ion from beneath th e ve hi c le. co ntrol leve r at th e transmi ss ion.
13. Support th e transmission assemb ly on a suitab le
CAUTION: After a long run th e transmission fluid will be hot c rad le and sec ure with chain . Owing to th e weig ht of
enough to cause serio us burns, th erefore suitable pre- th e assemb ly it is not reco mm end ed th at remova l or
cautions must be taken when removing th e transm iss ion . ins tallati on be und ert aken with out th e aid of a c rad le.
5. Di sco nn ec t th e speedometer cabl e.
14 . Rem ove th e engin e rea r mountin g to engin e rea r
6. Disco nn ec t th e oil coo ler hoses from th e transmission. cross member attach in g bolts.
To prevent dirt entry, plug both ho ses and transmission
15. Fo ld back th e loc k plates and remove th e two engine
co nn ec tors.
rear c ross membe r to fram e bo lts and wa shers (Refer
7. Disco nn ect detent switch and TCS switch conn ec tor Fig. 7-16 in the ' Man ual Transm iss ions' Secti on of thi s
from terminals in tran smi ss ion case. Man ual). Rem ove rea r c rossmember.
NOTE: Spacers are used between th e Engin e rea r mounting housi ng and its mating face on th e engin e are c lean
and transmiss ion extension with Turbo Hydramati c and fr ee from bu rrs. Also that th e co nvert er d ri ve pl ate
Tran smiss ions. to cranks haft attac hing bolts are co rrectl y tightened .
16. Lower th e transmi ss ion suffi c ientl y to gain access to 2. En sure th at the transmission locatin g dowels co m-
th e co nvert er housin g to engin e attaching bol ts. Ens ure pletely enter th e holes in th e conve rt er housing .
the di stributor ca p is not damaged as th e engin e is 3. Install th e conve rt er housing to engi ne bol ts and
lowered. ti gh ten bolts eve nly to 34 -44 Nm torqu e.
17. Rem ove th e co nverter housin g to engin e attach in g bolt 4. Pri or to install ing co nverter to drive plate attaching
holding th e fill er tupe and vac uum line. Before re- bo lts , ensure that th e markings mad e at tran smi ssion
moving th e fill er tube, ensure th e area about th e tube remova l are correc tly ali gned.
is clea n. Use a suitab le plug to prevent en try of dirt into
NOTE: Co nvert ers have a stripe of blue paint to indicate th e
th e transmi ss ion .
'light ' si de of th e assemb ly. If a new co nverter is fitted or
18. Positi on a suitable support und er th e engin e oi l pan to th e mark wa s not made d uring tran smission removal , it is
take th e weight of th e engi ne once th e tran smi ssion is important to index thi s blue balance mark on th e converter
rem oved. with th e co rres pondin g balance paint mark on th e con-
19. Remove th e rema in ing co nvert er housing to engin e ve rt er drive pl ate to maintain balan ce of th e cra nkshaft and
attac hin g bol ts and rem ove transmi ss in assembly. co nvert er.
20. In stall co nvert er holdin g too l number 7 A2 7 to preve nt 5. Install th e drive plate to conve rt er attac hin g bolts.
co nvert er beco min g d islodged . 6. Tighten conve rt er attaching bol ts to 34 -44 Nm .
7. Adj ust th e manual co ntrol linkag e as outlin ed in 'Min or
INSTALLATION
Se rvice Operati ons ', in th is Secti on.
NOTE: If th e tran smi ss ion ha s been removed and ove r-
8. Adjust the detent actuatin g switch as outlin ed in 'Min or
haul ed beca use of th e presence of foreign materi al suc h Se rvice Operati ons' in th e 'Trim ati c Tran smi ss ion'
as grit or metal parti cles, or if it is suspected that foreign Group in thi s Sec ti on .
matter has entered th e torqu e co nverter, it will be neces-
sary to flu sh out th e torqu e co nvert er, coo ler and co n- 9. Refill th e tran smi ssio n with 'DEXRON II ' automati c
nec ting pipes. For detail s, refer ' Flushin g Torqu e Co nvert er tran smission fluid as outlined in 'General Inform ation '
and Cooler Lin es' in th e Turbo Hydramati c Se rvi ce Manual. secti on of the Turbo Hydramati c Transmi ssion Se rvi ce
Manual.
In stallati on proced ure is th e reve rse of removal, however
1 0. Test th e tran sm iss ion oi l pressure as detailed in th e
parti cul ar attenti on should be paid to th e following points.
'Check in g and Diagnosi s' section of th e Turbo Hyd -
Refer Fig . 7-34 , for transmission in stallation de tai ls.
ramati c Service Manual and road test th e vehi c le to
1. Befo re offering th e transmission assembly up to the en sure that th e transmi ss ion operates co rr ectly.
engin e, ensure th at th e front fa ce of th e converter

Nm .
Drive Plate to Converter Bolts ................................. .... 34-44
Co nverter Housing to Engine Bolts .......................... .. 34 -44
Transm ission External Con trol Leve r Nut .. ........ ....... 11 -15
Engin e Rear Mountin g to Tran s. Extension Bolts .... 40-51
Engine Rea r Crossmember to Fram e Bolts ...... .... . .. 40-50
Eng in e Rear Crossmem ber to Rea r Mounting ......... 34 -46
MODULATOR PIPE
(~"·n,
......... - - '
·"':" _)
' j'
::--..._ r "-.
Z·~
'" "\";---/
BOLT3PLACES
I
~~
J
j
.t _ ~~
~
{I;
) /\J~''@'1. c(\
:J
.>- '
~-'
~ (0
);, '
\ ;:::.::_ ~ f 'Al
~- VIEW~
MATCH BLUE ~0-~RTER WITH
NT BALANCE
MARK ON CO BALANCE
WHITE PAI~~IVE PLATE.
MARK ON
I
((~
-- ju
.'
LUBRICATE RUBBER SEAL ON "'

TRANS. OIL LEVEL INDICATOR
WITH HN 1198TYPE 1 PRIOR
TO ASSEMBLY. _ _ _ _ _ ___,
;"'-j MODULATOR PIPE.

I t~
ASSEMBLE SEAL
INTO GROOVE
:(~COAT WITH
"-~:=!)'\:;}. HN 1198
-.'~""'-~ TYPE 1) . . .. (if ~
& 9 · 12 Nm.
:.~ liB z;:., (
..PTYPICAL
/ BOTH ENDS
& 34·44Nm. OF MODULATOR
Figure 7-34
Installation Details - Turbo Hydramatic Transmissi on.
SPRING IDENTIFICATION CHART
CODE 'EK' TURBO HYDRAMATIC TRANSMISSION
FREE
O.D .
COLOUR LENGTH TOTA L SPRING
SPRING DESCRIPTION INCHES
IDENTIFICATION APPROX . COILS PART NUMBER
N OMIN AL
INCHES
Detent Regulator Valve None 2.6 26 .5 .34 8623577
1- 2 Accumulator
Copper 1.4 15.5 .3 8625619
Primary Valve
1- 2 Regulator Valve Non e .87 13.5 .24 8623578
2- 3 Valve Red 1.5 17.5 .32 8626875
3- 2 Valve Yellow 2.4 18.5 .40 8623632
Pressure Regulator Valve Light Blue 3.3 13 .84 8625648
Front Servo Pi ston Non e 1. 1 4 1.25 8623489
Front Accumulator Pi ston Yellow 2.7 7.7 1.28 8625426
Re ar Servo None 2.2 12 .73 8623666
Rear Accumulator None 2.2 8.5 1.12 8623667
Governor White .63 9.5 .31 8626843
Governor Dark Green .9 9.5 .31 8626841
Forward & Direct

None 1.2 10.5 .45 8624101
Clutch Pi ston Return
Intermediate Clutch
None 1.0 11.5 .33 8623145
Piston Return
I -
/
SPECIFICATIONS
Gene ra l Data
Make. . . . . . . . . . . . .. ... . . . . . . . . . . . . . .... . . . Turbo Hydr amatic '400'
Type . . . . . . . . . ... ... . . . . . . . ... . . .. . ... . .. . Autom atic Hydraulic T orque Converter w ith 1
Compound Pl anetary Gear Syste m - Three

Forwa rd speeds and one Reverse.
Parkin g Lock
Type . . . . . . . . . . . . . . . . . . . . . . . .. .. · · · · · · · · · · Locking Pawl
Method of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water
Converter A sse mbly

Stall Ratio - : 1. .. ... . . . . . . . . . . . . . .. . .. ..... . 2. 10
Diameter - Nomi nal mm 309
Selector Le ver
Location . . . . . . . . . . . . . . . . Fl oor Mount ed
Operation . . . . . . ... . A ctuates Manual Valv e on Hy draulic V alve Body
Seque nce of Shi ft Positions . .... . 1. 2. D. N. R. P.
Gea r Rat io - : 1
D (Drive 3rd Gea r) . ... . . . ... .. .. . . . . . . . . . . . . 1.00
2 - (Second) .. . .. . . . . . . . . . . . .... . .. . . .. ... . 1.4 8
1 - ( Low) . . . . . . . . ..... .. .... .. .. . . . .... . . . 2.48
R - (R everse) . . . . . . . . . . . .. . . .. . .. .. .... . ... . 2.08
Cl utch es
Type . ... .. .. .. . . . . . . . . . . .... . .. · .. · · · · · · · Multip le Wet Di sc
Plates Steel (Flat) Composition Steel (Waved)
Forward Clutch . . . . . . . ... .. . . .... . .. . . . . . . . . . . . 4 5 1
Direct Clutch ... ..... ... . ... ... . ...... . .. .... . 4 5
Intermediate Clutch .. ... . . . . . . . . .... .. . . . . .... . . 2 3
Lubri ca nt
~~ · ····· ··· · · ···· ········· · · ····· .. . " Dexron II"
Capac ity - Litres - Dry - Inc ludin g Conve rter . . .. 10.4
Refill . . . . . . . . ..... ... .. .... .. . . . . . . . . . . . . 3.7
SHIFT SPEED CHA RT k m/h
UPSH IFT DOWNSHI FT
CLO SED FUL L CLOSED FUL L

TH ROTTLE TH RO TT LE THR O TTLE THROTTLE
1- ·2 2- 3 1-2 2- 3 2- 1 3- 2 3- 2 2- 1
13 - 16 34 - 39 63-71 105 - 12 1 13 - 16 29 - 34 97 - 109 39 - 45

FUEL TANK & EXHAUST SYSTEM 08-01
SECTION 08
FUEL TANK AND EXHAUST SYSTEM
L6 AND V8 ENGINES
Subject Page
FUEL TANK ....................................................................... 08-01
EXHAUST SYSTEM .......................................................... 08-09
FUEL TANK
INDEX
GENERAL INFORMATION .............................................. 08-Q1 FUEL TANK ....................................................................... 08-06
FUEL TANK FILLER CAP ............................................... 08-Q1 REMOVAL .................................................................. 08-06
FUEL GAUGE TANK UNIT ............................................. 08-01 INSTALLATION .......................................................... 08-Q6
FUEL TANK VENTING .................................................... 08-Q5 SPECIFICATIONS ............................................................. 08-07
SERVICE OPERATIONS ................................................. 08-05 TORQUE WRENCH SPECIFICATIONS ........................ 08-Q7
FUEL GAUGE TANK UNIT ............................................. 08-05 SPECIAL TOOLS .............................................................. 08-07
REMOVAL .................................................................. 08-05
INSTALLATION .......................................................... 08-06
GENERAL INFORMATION
The fuel tank and its associated venting is an integral part It has built-in spring loaded pressure and vacuum valves.
of the evaporative emission control system. The tank has If, due to some malfunction or restriction in th e EEC
a fuel capacity of 63 litres, has an underslung mounting canister vent system, pressure bu ilds up in the tank to
and is retained by two straps bolted beneath the rear approximately 1 psi, the pressure relief valve in the cap
compartment floor. The fuel and vapour lines are routed opens venting the tank to atmosphere. The same protection
outside the body (Fig . 8-1) . exists if vacuum in the tank builds up. The vacuum vent
valve in the cap opens, relieving the excess vacuum in the
A plastic fill limiter pot with a capacity of approximately tank.
three litres is located inside the fuel tank. The purpose of
the fill limiter pot is to provide fuel overfill control by A locking fuel tank cap is standard equipment on the 8VX
maintaining a guaranteed air space in the tank to allow for models and available as an option on other VB models.
expansion of the fuel. The communication between the fill
limiter pot and the tank proper is through a 1mm diameter
orifice in the underside of the pot. The fill limiter pot is FUEL GAUGE TANK UNIT
vented to the fuel tank filler neck by two pipes. For practical
purposes, the fill limiter pot is part of the tank and no The fuel gauge tank unit is retained in the front vertical face
service work is possible on it. of the fuel tank. A fine mesh strainer is attached to the lower
end of the tank unit riser pipe (Fig . 8-2) . The unit is retained
FUEL TANK FILLER CAP in the tank by a cam lock arrangement. A seal is located
between the flange on the unit and the tank. On models with
The fuel filler cap is located behind a hinged door on the
5 litre engine, Turbo Hydramatic transmission and air
right hand rear quarter panel.
conditioning, a vapour return system is used . The vapour
The fuel filler cap is not vented under normal conditions. return line enters the tank at the tank unit flange .
0
co
I
0
.,c
1\)
VAPOUR PIPE m
r-
~
FUEL PIPE VAPOUR RETURN PIPE
-VAPOUR RETURN PIPE
A-A
z
"m
SECTION
Qo
~
@] ><
J:
t...
,
:t>
c
~
~ CJ)
~
FUEL PIPE
BRAKE PIPE
FUEL PIPE
~
~'
J ~m
VAPOUR PIPE
VAP .RETURN PIPE ~ s::
VAPOUR PIPE
~
y
L CLIP
SECTION B--8 VIEW[£]
)
BEND OVER CLIPS TO SECURELY
RETAIN ALL PIPES
VIEW~
VIEW~
Figure 8-1
Fuel and Vapour Line Routing
STRAINER
Figure 8-2
Fuel Gauge Tank Unit
REAR FRAME
ENSURE HOSE DOES NOT KINK

DURING ASSEMBLY WHEN
PASSING OVER FRAME
SECTION B-B
VAPOUR RETURN LINE

USED WITH
L31 & M41 & C60
HOSE TO
REINFORCEMENT
FUEL LINE
(4 PLACES) REINFORCEMENT
BRACKET ROD
ASM .
ffi BOLT
CROSSMEMBER
(3 PLACES)
SECTION A-A
FLOOR PAN
REAR FRAME
NUT ill
SECTION C-C
ffi 26-32 Nm
ffi 40-51 Nm
SECTION 0-0 FOR VIEWS ~ { lli] REFER FIG. 8 - 4
Figure 8-3
Fuel Tank Installation and Mounting Details
0
Q)
I
0
~
--------,~ ~ / ,PANEL__.----~·,
"T1
c
I//?! .~
,--:;~/;/
,//. / TER INNER PANEL
m
/.·~~/ ~\ r-
LEAK-OUT
o / \_ / PREVENTIONVALVE
~
(I I ,/ '~, z
"m
u~/;'i~\ \
HOSE J E-PIECE
RO
TO Fl LLER NECK
><
:::r:
HOSE RESERVOIR \ TO CANISTER
c>
VAPOUR(INE
TO FILLER NECK
11;4 .1 \ FUEL FILLER HOSE RESERVOIR
' I/ I I STONE GUARD
TO Fl LLER \ECK
~
!Iv
r~ :
I·
I .
HOSE-FILLER VENT
~
CJ)
<
1. ~ ~
sEAL WITH I BREATHER RESERVOIR
I NON-PORITE I m
y( \I', \
I G /~L:2.
r\··
FILL LIMITER !
3:
VENT LINE
/ \\~\·\
~~
). ~I / .·
SCREW&
\ \ H fr="_) (
\ 1~ ~~}~I
\
·~v \\~
SECTION G- G
'c? lJ=o \: \\
- I (\ I I \\ c '~ \
VIEW~ VIEW FROM FRONT OF CAR VIEW[§]
(STONE GUARD OMITTED)
ffi 3.6 - 5 .0Nm
Figure 8-4
Fuel Tank Vent Hose Routing and Stone Guard
POT
l NECK
FILL VENT LINE
FUEL TANK
Figure 8-5
Fuel Tank Venting Schematic
FUEL TANK VENTING purpose of the breather reservoir is to ensure adequate

scavanging of the vent pipes and to act as a 'Surge Pot'
Fuel tank venting is such that no matter what attitude the during violent vehicle manoeuvring.
vehicle assumes, venting is adequate tQ prevent a pressure
build up in the tank. The fuel tank filler neck is vented to the EEC canister by
Three vent pipes exit from the fuel tank (Fig. 8-3). The a hose, pipe and leak out prevention valve. The leak out
larger diameter pipe is the fill ventilation line and connects prevention valve is a simple ball type, one way valve who's
the upper area of the tank with the filler neck and is the function is to prevent raw fuel entering the canister line.
venting medium as the tank is filled with fuel. The smaller Fig. 8-5 shows a schematic representation of the venting
diameter pipes vent the left hand front and left hand rear system.
corners of the tank together with the fill limiter pot to the
filler neck through a breather reservoir clamped to the The fuel tank filler neck and vent pipes and hoses are
outside of the filler neck (Fig. 8-4). Two hoses leave the located under the right hand rear fender. A fuel filler stone
reservoir, attach to a 'Tee' piece and a single hose con- guard is utilized to prevent damage to these components
nects the 'Tee' piece to the filler neck connection . The and also to prevent mud build up. Refer Fig. 8-4.
SERVICE OPERATIONS
FUEL GAUGE TANK UNIT 4. Install Tool No. AU 140 on gauge unit and rotate unit
in an anti-clockwise direction.
REMOVAL 5. Remove unit from tank.
1. Place the vehicle on jack stands and drain the tank
through fuel filler opening using a commercially
available fuel syphoning device. CAUTION: Care should be exercised during removal of
2. Disconnect the fuel line and vapour return line (if fitted) gauge unit from the tank not to damage the filter on the riser
from gauge unit. pipe. Before installing the assembly into fuel tank, clean the
3. Disconnect the electrical feed and earth cables from screen by blowing off carefully with compressed air; re-
unit. Refer Fig. 8-6. place if damaged or unable to clean.
08-06 FUEL TANK & EXHAUST SYSTEM
EXTERNAL 2. Remove filler neck stone guard under the right hand
fender. Refer Fig . 8-4.
3. Disconnect the fuel line and vapour return line (if fitted)
from the gauge unit.
4. Disconnect the electrical feed and earth cables from
gauge unit.
5. Disconnect the large diameter fuel tank vent hose at
fuel tank filler neck.
LEAD ASM.
NOTE: This hose passes over the frame and between the
@ a~ SENDER EARTH
frame and body.
~ I
6. Disconnect the fuel tank to canister vapour hose from
vapour pipe at front of tank.
7. Support fuel tank with a suitable jack. Locate a block
~""" '\ of wood between the jack and tank to prevent damage
LEAD ASM . SENDER
to tank.
Figure 8-6 8. Remove the bolts and nut securing the fuel tank straps
to the body (Refer Fig . 8-3) and lower tank.
Fuel Gauge Tank Unit Electrical Connections
CAUTION: Guide large diameter vent hose between frame

and body as the tank is lowered.
NOTE: It is not necessary to remove the filler neck to body
NOTE: Refer 'Instruments and Gauges' in the Electrical seal when removing the tank, however a coating of
Section of this Manual for fuel gauge tank unit test pro- petroleum jelly will assist when sliding the neck through the
cedures . seal.
INSTALLATION INSTALLATION
Reverse to removal operations noting the following. Installation procedures are reverse to removal noting the
1. Install seal between the gauge unit flange and tank. The following .
seal may be lubricated with petroleum jelly, if desired, 1. Lubricate upper end of filler tube with petroleum jelly
to assist assembly. to assist when installing neck through neck seal.
2. Install gauge unit using tool AU140. 2. Before finally positioning the tank, plug the large
diameter vent hose to prevent dirt entry and pass it
over the frame between frame and body.
NOTE: Remove the plug when the hose end is clear of the
FUEL TANK frame. Ensure that the vent hose is not kinked or twisted
prior to attaching it to the filler neck connection.
REMOVAL 3. Install strap attaching bolts and nut and tighten to the
1. Place vehicle on jack stands and drain the tank by torque values shown in 'Torque Wrench Specifications '
syphoning out the fuel through the fuel filler opening in this section .
using a commercially available fuel syphoning device. 4. Install the filler neck stone guard .
SPECIFICATIONS
FUEL TANK
Type . . . . . . . . . . . . . . . . . . . . Basic rectangular shape incorporating built in
fill limiter pot. Venting is via three pipes to
filler neck and charcoal canister.
Location . . . . . . . . . . Externally strap mounted under rear compartment floor.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 litres
Filler Location ... Concealed beRind a hinged door in right hand quarter panel.
FUEL GAUGE TANK UNIT

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GMH
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Resistance Specs. (Ohms)
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B2
Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 40
Filters . . . . . . . . . . . . . . . . Primary filter for initial dirt and water filtration in
fuel tank on riser pipe, combined with fuel gauge
tank unit. Second filter in the following locations:
L6 Engines - in fuel pump
4.2 VB Engines- on fuel pipe
between pump and carburettor.
5.0 VB Engine - in carburettor.

Nm
Fuel Tank Support Strap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-51
Fuel Tank Support Strap Nut ..... . . . . . . . . . . . . . . . . . . . . . . . . . 26-32
SPECIAL TOOLS
AU140 . . . . . . . . . . . . . . . . . . . . Fuel gauge tank unit remover and installer.
08-08 FUEL TANK & EXHAUST SYSTEM
NOTES
EXHAUST SYSTEM
INDEX
GENERAL INFORMATION .............................................. 08-09 SPECIFICATIONS ............................................................. 08-Q9
SERVICE OPERATIONS ................................................. 08-09 TORQUE WRENCH SPECIFICATIONS ........................ 08-Q9
GENERAL INFORMATION
A single exhaust system with two mufflers is standard A dual exhaust system option is available on Models with
equipment for all VB Models with L6 engines (Fig. 8-7). a VB engine and includes separate mufflers connecting with
Models with VS engines have a single system, similar to the a common rear muffler. (Fig. 8-9). In all systems, the ex-
L6 type, but with a front cross over pipe as standard haust pipe and tail pipe are made of seam welded
equipment (Fig. 8-8). aluminized steel tube.
SERVICE OPERATIONS
When installing the exhaust system, care must be taken to that the correct assembly, installation and tightening se-
install each part or assembly in correct relation to one quence and clearance for the system involved are obser-
another. Incorrect assembly of exhaust system components ved. Refer Figs. 8-10, 8-11, 8-12 and 8-13 for details.
can frequently be the cause of rattles or 'booms' due to
incorrect alignment or clearance from the body or sus- When installing the exhaust flange to manifold nuts, apply
pension parts. anti- seize compound to GMH Specification HN 1325 to the
When assembling and installing the exhaust system, ensure manifold stud threads.
SPECIFICATIONS
VB L6
Type .. . ... Single with crossover·standard ..........................Single
Dual system-optional
Muffler ... . ... Standard system- as for L6 ..................... Two Mufflers
Optional dual system-3 mufflers
Exhaust Pipe
Branch-O.D. wall thickness. mm .. 4 7.6 x 1.6 ........ ....... .. ... ..... . None
Main-O.D. wall thickness . mm ... 50.0 x 1.6 ....................... 50.0 x 1.6
Material ....... .. Seam welded steel tube .............. Seam welded steel tube
Tail Pipe
O.D. and wall thickness. mm .... 50.0 x 1.6 ........ .......... ..... 50.0 x 1.6
Material .. Seam welded aluminized steel tube ...... Seam welded aluminized steel tube

Nm
Exhaust pipe flange to manifold(s) nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Exhaust pipe clamp nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
0
co
ASSEMBLY 't
APPLY ANTI-SEIZE
COMPOUND HN1325-
TO STUDS BEFORE r(
IJEI~.'
j f
SUPPORT RING
~BUMPER
SUPPORT
0
I
......
"T1
c
m
r-
~·
RING
~
=-::;j z
£
"m
RO
£ ><
J:
)>
c
~
tJ)
-<
~
-- - \ / 7 > - _ __
'------=--;:/
l m
3:
FRONT EXHAUST
PIPE
TAIL PIPE , EXTENSION
~;:NG7
8VXONL Y ~ £ 24 - 32Nm
& 12 - 16Nm
FOR SECTIONS REFER EXHAUST CLEARANCES FIG . 8 - 11
Figure 8-7
Exhaust System Layout - L6 Engines
'U' BOLT
ASM.
~- @]
--I
"T1
'\ c
'' m
' - - - - - __ ./7)...._- -
...___::._.// .
r
c MUFFLER & PIPE ASM. ;!
z
I
-:.~-- MUFFLER & TAIL PIPE ASM. I
"m
Qo
><
:I:
:t-
TAIL PIPE EXTENSION
c
PRESS FIT E~NTIRE
LENGTH ~
CJ)
------ '(} c:::s
l::f/s::::, ffi -<
~
24-32 Nm
8VX ONLY --
& 12-16 Nm FOR SECTIONS REFER EXHAUST CLEARANCES FIG. 8- 12 m
s::::
0
CIO
Figure 8-8 I
Standard Exhaust System Layout - VB Engines

..a.
..a.
0
co
.....
I
1\)
"T1
c:
m
r-
);!
z
,:::
Ro
m
><
J:
)>
c:
~
en
~
m
3:
LBUMPER - - TAIL PIPE EXTENSION
[F] 2 PLACES (8VX ONLY)

PRESS FIT ENTIRE LENGTH
Figure 8-9
Exhaust System Layout - V8 Engines With Optional Dual System
EXHAUST SYSTEM FITMENT & TIGHTENING SEQUENCE
8 A. ATTACH FRONT PIPE LOOSELY TO MANIFOLD .
~. ~~vc
B. HOOK FRONT PIPE TO BODY MOUNT HOOKS
c. HOOK TAIL PIPE TO BODY MOUNT HOOKS
A D. BEND TABS ON END OF ALL BODY MOUNT HOOKS UPWARDS
2 1. INTERMEDIATE PIPE TO REAR MUFFLER
1 2. FRONT PIPE TO INTERMEDIATE MUFFLER
3 3. FRONT PIPE TO MANIFOLD
6 CYLINDER
A. ATTACH FRONT PIPES LOOSELY TO MANIFOLD

B. HOOK INTERMEDIATE FRONT PIPE TO BODY MOUNT HOOKS
c. HOOK TAIL PIPE TO BODY MOUNT HOOKS
c
lo,~~
8 D. BEND TABS ON END OF ALL BODY MOUNT HOOKS UPWARDS
1. INTERMEDIATE PIPE TO REAR MUFFLER
2. INTERMEDIATE FRONT PIPE TO INTERMEDIATE MUFFLER
2 1 3. FRONT PIPE TO INTERMEDIATE FRONT PIPE
4. FRONT PIPES TO MANIFOLD
"T1
3 c
m
r
8 CYLINDER STANDARD SYSTEM
;!
z
A
A.
B.
c.
ATTACH FRONT PIPES LOOSELY TO MANIFOLD
HOOK INTERMEDIATE FRONT PIPES TO BODY MOUNT HOOKS
HOOK TAIL PIPE TO BODY MOUNT HOOKS
"m
Ro
D. BEND TABS ON END OF ALL BODY MOUNT HOOKS UPWARDS ><

:I:
1. INTERMEDIATE MUFFLERS TO INTERMEDIATE PIPES
.JC 2. FRONT PIPES TO INTERMEDIATE FRONT PIPES )It
3. TAIL PIPE SUPPORT c
~~
3 4.
5.
FRONT PIPES TO MANIFOLD
LH PIPE TO RH PIPE ~
4 2 CJ)
-<
~
m
8 CYLINDER DUAL SYSTEM
s:
0
coI
Figure 8-10 ......
Exhaust System Fitment and Tightening Sequence ttl
0
Q)
I
""""
~
CROSSMEMBER "T1
c
FLOOR PAN m
ASM. r-
~CLUTCH HOUSING
;!
19.0mm ~ z
"m
Qo
><
::I
SECTION A- A SECTION 8-8 SECTION C- C )>
c
SECTION E- E ~
(J)
~
<
......~
REAR FLOOR PAN ~
69 STYLES 17.0mm m
3:
~-M-B_E_R ____
SECTION G- G
REAR MUFFLER
SECTION F- F
FRONT MUFFLER (69 STYLES)
SECTION 0- D
Figure 8-11
Exhaust System Clearances - L6 Engines
CYLINDER & CASE fSUSeENSION ENGINE
STEERING RACK HOUSING FLANGE REAR BRACKET ASM.
p I'•D
""" FLOOR PAN
17.0mm MOUNTING FLANGE FOR

STARTER MOTOR SOLENOID SECTION C- C SECTION D- D
SECTION A-A SECTION B- B REAR FLOOR PAN
FRONT MUFFLER
REAR MUFFLER
CROSSMEMBERl .,c
m
r-
22.0mm
~
z
SECTION G- G
SECTION E- E
(69 STYLES)
LOWER BACK PANEL

"m
RO
><
J:
~
)>
c
~
17.0mm 69 STYLES
SECTION F- F en
<
SECTION H- H
~
m
s:::
0
co
I
Figure 8-12 ......
Exhaust System Clearances - VB Engines, Except Dual System U1
0
Q)
I
...L
GAR SU:PENSION BRACKET

.,c:
0)
POWER STEERING RACK ENG. REAR MOUNTING

m
r-
~
17.0 mm z
~ARKING BRAKE CABLE

"m
Qo
><
SECTION A- A
SECTION C-C
\, '
15.0 mm
J:
)>
c:
~
SECTION 8- B (J)
<
~
m
SECTION D- D s::::
LOWER BACK PANEL

IPANHARD ROD
MOUNTING BRACKET
SECTION H- H
SECTION J- J
Figure 8-13
Exhaust System Clearances - VB Engines, With Dual System
STEERING 09-01
SECTION 09
STEERING
Subject Page
STEERING COLUMN ASSEMBLY ................................. 09-01
MANUAL STEERING ........................................................ 09-09
POWER STEERING ......................................................... 09-15
STEERING COLUMN ASSEMBLY

INDEX
GENERAL DESCRIPTION ............................................... 09-01 STEERING COLUMN ASSEMBLY ................................. 09-05
MINOR SERVICE OPERATIONS ................................... 09-02 REMOVAL .................................................................. 09-05
STEERING WHEEL .......................................................... 09-02 INSTALLATION .......................................................... 09-05
REMOVAL .................................................................. 09-02 LOWER STEERING COLUMN BEARING ................... 09-07
INSTALLATION .......................................................... ()9-02 REMOVAL .................................................................. 09-07
IGNITION & STEERING LOCK ...................................... 09-02 INSTALLATION .......................................................... 09-07
REMOVAL .................................................................. 09-02 INTERMEDIATE STEERING COUPLING ...................... 09-07
IGNITION SWITCH ........................................................... 09-03 INSTALLATION .......................................................... 09-07
INSTALLATION .......................................................... 09-03 SPECIAL TOOLS .............................................................. 09-07
MAJOR SERVICE OPERATIONS .................................. 09-05
STEERING COLUMN SHAFT ......................................... 09-05
REMOVAL .................................................................. 09-05
INSTALLATION .......................................................... 09-05
GENERAL DESCRIPTION
An Energy Absorbing steering column is fitted to all VB CAUTION: The outer mast jacket, steering shaft, and
Models and is designed to compress under impact from instrument column mounting bracket are designed as
either direction. energy absorbing units. Because of the design of these
The ignition switch and steering lock are mounted to the components, it is absolutely necessary to handle the
steering column. The steering wheel is automatically locked column with care when performing any service operation
when the ignition lock is in the 'Locked ' position and the required. Avoid hammering, jarring, dropping or leaning on
key is removed from the lock. any portion of the column.
The intermediate steering coupling, which connects the
steering column to the steering gear, features two universal
joints and a fabric joint at the upper universal.
09-02 STEERING

STEERING WHEEL REMOVAL
1. Disconnect battery ground cable .
REMOVAL 2. Remove steering wheel as previously outlined .
1. Disconnect battery ground cable. 3. Remove screws attaching upper and lower covers from
2. Remove two horn bar to steering wheel screws from column.
underside of steering wheel, raise horn bar and dis- 4. Unclip and disconnect harnesses from connectors.
connect wiring connector. (Fig. 9-1) 5. Unscrew hazard warning knob.
3. Remove lock nut and steering wheel retaining nut. 6. Remove screws attaching indicator switch and lever
4. Remove steering wheel using two M8 x 1.25 bolts assembly to steering column housing assembly and lift
76 mm long, in conjunction with body and spindle bolt assemblies and harnesses out of column .
of Tool No. 9A1-1 . 7. With the lock in the OFF position, insert a small
screwdriver or suitable tool into the turnsignal housing
INSTALLATION slot, (Fig . 9-3) depress latch on inner end of cylinder
1. Install steering wheel ensuring spoke position is cor- and remove cylinder from housing.
rect. NOTE: For key coding see Group 1 in this manual.
2. Torque retaining nut to 19 - 22 Nm and lock nut finger
tight plus 1/4-1/3 turn.
INSTALLATION
3. Reconnect horn bar wiring connector and install horn
bar retaining screws from underside of steering wheel. 1. Insert cylinder into housing bore aligning key on
(No horn contact adjustment is provided) . cylinder sleeve with keyway in housing . Rotate cylinder
using light pressure until drive section of cylinder
mates with sector and push in until spring latch en-
IGNITION AND STEERING LOCK gages slot in housing.
2. Check cylinder for freedom of rotation . Must spring
The combination ignition and steering lock is located on freely back from START to ON position.
the right hand side of the steering column. The steering
lock is actuated when the 'lock' position is selected and the 3. Install switch and lever assemblies, reverse removal
key removed. This causes a 'bolt', attached to the rack, to operations.
engage the lock plate on the underside of the steering 4. Install steering wheel assembly as previously outlined.
wheel. (Fig . 9-2).
S ECTION A A I
FINGER TIGHT PLUS
1/4 ·- 1/3 TURN-
~
f/
#-r
- ·-
--~
\,, ~-- ~-/'A
'
~
'(;.'.- ...~
I
~~
. I
-- ,:
1!\~c :--J ,.:.~,
~_ -y--·
. ,..
~-
I A~
~
-_-- I
~--
"\,___
-
---- I //
L ' A T ELECTRICAL
CONTACT SURFACE
WITH HN 1346 ffi 19-22 Nm
Figure 9-1
Steering Wheel Installation
STEERING 09-03
IGNITION SWITCH
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on the
end of the lock cylinder, thus enabling the rod and rack to
be moved axially (with respect to the column) to actuate
the switch when the lock cylinder is rotated.
REMOVAL
1. Remove or lower the steering column as outlined under
heading 'Steering Column Removal' later in this sec-
tion.
CAUTION: If the steering column is not removed from the

vehicle, be sure that it is properly supported before pro-
ceeding.
2. The switch should be positioned in 'Lock' position
before removing. If the lock cylinder has already been
removed, the switch should be locked in the lock
position using a 3/32 in. diameter gauge pin inserted
in the hole provided . (Fig. 9-4) .
3. Remove the two switch mounting screws and remove
STEERING WHEEL RAISED the switch assembly.
TO SHOW LOCK PLATE AND BOLT
INSTALLATION
1. Before replacing the switch , be sure that the lock is in
the 'Lock' position .
Figure 9-2 2. Lock the switch in the 'Lock' position using a 3/ 32 in.
Steering Lock Plate and Plunger diameter gauge pin inserted in the hole provided in the
switch body (refer Fig . 9-4) . If necessary a screwdriver
placed in the locking rod slot can be used to move the
switch until the pin falls into the engaging hole.
3. Install the actuating rod into the switch and assemble
the switch on the column: tighten the mounting screws.
CAUTION: Use only the specified screws since over length

screws could prevent a portion of the assembly from
compressing under impact.
4. Reinstall the steering column assembly as outlined
under heading 'Steering Column Installation' later in
this section.
Figure 9-3
Depressing Lock Cylinder Latch
0
U)
I
0
.l:ao
~
m
I LOCKING BARREL MUST NOT KEY MUST BE IN THE 'ON' m
~\(J /;
SEPARATE FROM STEERING OR 'OFF' POSITION BEFORE
-::rJz
-
COLUMN HOUSING' WHEN ASSEMBLY TO STEERING
A FORCE OF 67N IS COLUMN-
APPLIED IN DIRECTION OF C)
ARROW J
I I .....
'~\
/
/
!' '/)~
. !_/'-.." ',
/ I ~
NOTE:- PLASTIC GUIDE MAY BE '~
ADJUSTED TO ACHIEVE ~
SATISFACTORY SWITCH OPERATION
(LUBRICATE WITH MOLYBDENUM
DISULPHATE GREASE HN1271 GRADE 2)
LOCK SWITCH IN 'LOCK' POSITION USING

A 2,34 mm DIA. GAUGE PIN INSERTED IN
THIS HOLE. SET LOCKING BARREL IN 'LOCK' IGNITION SWITCH
POSITION & REMOVE KEY. SLIP SWITCH '
OVER CRANKED END OF OPERATING ROD
AND INSTALL SCREWS IN THIS POSITION.
\=::::::::::::----
(
-- --
TIGHTEN SCREWS 3,4-4,5 Nm AFTER
SCREWS HEADS HAVE BEEN FIRMLY SEATED.
YIEW [d] 3 PLACES _&
ffi 4.5-6.5 Nm
Figure 9-4
Ignition Switch and locking Barrel
STEERING 09-05

STEERING COLUMN SHAFT 2. Remove upper and lower covers from column .
3. Remove heat and vent ducts to instrument panel outlet.
REMOVAL 4. Raise rubber grommet at base of column and remove
1. Disconnect battery ground cable. intermediate to steering shaft clamp bolt.
2. Remove turn signal switch, lever assembly and lock 5. Remove bolt attaching column bracket to floor pan .
cylinder as previously outlined . 6. Disconnect electrical connectors at column .
3. Remove rubber grommet at base of column and re- 7. Remove nuts attaching column mounting bracket to
move bolt from clamp securing steering shaft to in- instrument panel and lift assembly up and out of
termediate shaft. vehicle.
4. Remove screws securing column housing and dis-
connect link to ignition switch while removing housing .
5. Remove nuts attaching column assembly bracket to
instrument panel and support column assembly in the
lowered position . INSTALLATION
6. Withdraw shaft assembly from column and remove 1. Align cut out in steering shaft with notch in inter-
upper circlip, spring and washer and remove housing mediate shaft and install clamp bolt loosely.
from shaft. (Fig. 9-5) . 2. Install column bracket to floor pan bolt finger tight.
3. Install column assembly to instrument panel attaching
INSTALLATION nuts and torque to 12-16 Nm .
Replace in reverse order, aligning cut out in steering shaft 4. Torque clamp bolt to 12-16 Nm and install rubber
with notch in intermediate shaft and torquing clamp bolt to boot.
16-22 Nm. Apply sealer HN 1394 into groove in grommet 5. Torque bolt attaching steering column bracket to floor
prior to installation to dash panel. pan to 40-51 Nm and apply sealer HN1394 into
groove in grommet prior to installation to dash panel.
STEERING COLUMN ASSEMBLY 6. Reconnect electrical connectors at column .
7. Install upper and lower steering column covers.
REMOVAL 8. Install heat and vent ducting.
1. Disconnect battery ground cable . 9. Reconnect battery ground cable.
ADD SEALER HN 1394

AROUND SHELL OF SEAL
AFTER INSTALLATION
) JACKET & CAPSULE

STEERING SHAFT ASSY RING
I COVER
SPRING
ADAPTOR & BEARING
ASSY .
I
( ~1,
0 0
\ ~GHTEN SCREW AT ASSY . 5,5 - 8,0 Nm
AFTER SCREW HEAD HAS BEEN FIRMLY SEATED
Figure 9-5
Section View of Steering Column
0
CD
I
0
COVER I 1c:n
~
m
m
:!!
z
C)
I I
COVER
CCAMe~ ' '\-f
r-;~- ,,~0~
'i ;,
A--:8\,r~~,)~
~~- 0 '·
*&
2 PLACES~
,L1
........--- &\ PLACESr\\
£CLIP :&4
3 PLACES ~
GROMMET
ADD HN 1394 TO FULL

CIRCUMFERENCE OF GROOVE
IN GROMMET PRIOR TO
~
To
INSTALLATION
2Nm
44 - 60 Nm
40 - 51 Nm
SECTION A -A
& MANUAL STEERING POWER STEERING FITMENT OF GROMMET
4
12-16Nm
TO DASH PANEL
3 .6 - 4 .6Nm
;~_':; 16-22 Nm
Figure 9-6
Steering Column & Intermediate Coupling Assemblies
STEERING 09-07
LOWER STEERING COLUMN BEARING steering gear and withdraw assembly (Fig. 9-6).
b. POWER STEERING - Loosen lower flange bolt,
REMOVAL remove upper flange bolt and withdraw assembly
(Fig . 9-6).
1. Remove steering column as previously outlined.
2. Pry out seal from bottom of column .
3. Remove retaining clip from lower end of housing and
pry out lower bearing from housing . (Fig. 9-5) INSTALLATION
INSTALLATION 1. a. MANUAL STEERING - Install coupling onto
Reverse removal procedure taking care not to apply force steering gear shaft aligning notch in shaft with
or hammer bearing into place and apply sealer HN1394 to attaching bolt bole in coupling and loosely install
lower column seal shell. attaching bolt.
b. POWER STEERING - Install coupling into flange
aligning notch in coupling with attaching bolt hole
in flange and loosely install attaching bolt.
INTERMEDIATE STEERING COUPLING 2. Install steering column assembly as previously outlined
and torque upper clamp nut to 44-60 Nm.
REMOVAL 3. Install coupling bolt (Manual Steering) or upper flange
1. a. MANUAL STEERING - Disconnect coupling from bolt (Power Steering) and torque to 16-22 Nm.

Nm
Steering wheel nut ............................................................ 19-22
Steering wheel lock nut .... Finger tight plus 114-1 /3 turn
Support bracket to instrument panel nuts ................. 12-16
Support bracket, column to floor pan bolt ................ 40-51
Steering to intermediate shaft clamp nut .................. 44-60
Flange to coupling to steering gear bolt(s) .............. 16-22
SPECIAL TOOLS
9A 1-1 Steering wheel puller (Use with 2 - MB x 1.25 bolts, 76 mm long).
09-08 STEERING
NOTES
STEERING 09-09
MANUAL STEERING
INDEX
GENERAL DESCRIPTION ............................................... 09-09 DIAGNOSIS GUIDE .......................................................... 09-14
SERVICE OPERATIONS ................................................. 09-09 SPECIAL TOOLS .............................................................. 09-14
STEERING GEAR ASSEMBLY ...................................... 09-09 SPECIFICATIONS ............................................................. 09-14
DISASSEMBLY .......................................................... 09-09
CLEANING & INSPECTION ..................................... 09-09
REASSEMBLY ........................................................... 09-09
INSTALLATION .......................................................... 09-13
GENERAL DESCRIPTION
The manual rack and pinion steering gear is standard on housing and is supported at one end by a bush and at the
all six cylinder models and is solidly mounted to the rear other by a spring loaded yoke, which also maintains en-
of the front crossmember. gagement of the rack and pinion. Tie rods are connected
The helical tooth pinion is supported in the steering to each end of the rack by ball joints and to the steering
housing by ball bearings. The rack operates within the arms by sealed tie rod end ball joints. (Fig. 9-7) .
09-10 STEERING
SERVICE OPERATIONS
STEERING GEAR ASSEMBLY REASSEMBLY
For identification of parts, refer Fig . 9-7 and 9-7 A.
REMOVAL 1. Place steering gear housing in an inverted position in
1. Remove steering lower coupling bolt and upper clamp a soft-jawed vice or suitable fixture and fit nylon rack
bolt. bush using a suitable piece of tube. Ensure ears of
2. Raise front of vehicle and place on stands. bush are correctly located in housing groove. Fig. 9-7.
3. Remove ball studs from steering arm tapers using 2. Lubricate and install pinion upper bearing into
suitable puller. housing .
4. Remove bolts attaching steering gear assembly to 3. Insert rack into housing from pinion end, aligning teeth
crossmember (Fig. 9-8) and remove steering gear, with pinion bore.
sliding gear from coupling . 4. Locate rack so that it protrudes an equal amount at
each side of housing.
5. Assemble upper pinion bearing spacer to pinion .
DISASSEMBLY 6. Insert pinion into mesh with rack. Ensure that flat on
For identification of parts, refer Fig. 9-7 and 9-7 A. pinion shaft is opposite timing mark on housing. i.e.
1. Remove tie rod ball joint and lock nuts. straight-ahead position .
2. Release clamps securing rubber boots to steering 7. Lubricate lower bearing assembly and assemble to
housing and tie rods, then remove the boots. pinion shaft and housing.
NOTE: Perform operation over a suitable container to catch 8. Select a shim stack which when assembled with lower
oil which will drain from the steering gear. Allow all oil to spacer gives a feeler gauge gap of 0.22 -0.27 mm
drain and wipe assembly dry. between cover plate and housing.
3. Secure steering gear in a bench vice having soft jaws NOTE:
and drill out pin securing locknut and ball housing to a. Gap measured without gasket fitted.
rack using a 5/32" drill. b. Gap measured with cover bolts only nip or finger tight.
4. Remove ball joint housings and tie rods using special c. Stated gap above is equivalent to a bearing clearance
tools 9A38 and AU169 . Remove ball seats, springs and of 0.025-0.076 mm when new gasket is fitted and
lock nuts. cover bolts torqued to 17-21 Nm .
9. Remove cover plate, add new gasket and torque cover
CAUTION: When removing, use an adjustable wrench on flat
bolts to 17-21 Nm.
teeth of rack to prevent rotation and possible damage to
the rack or pinion teeth. Be careful not to nick or damage 10. With rack in straight ahead position, install yoke and
rack on yoke side. cover. Do not fit yoke spring at this stage. Lightly
tighten cover bolts, and with a feeler gauge, measure
5. Remove two bolts retaining rack yoke cover plate.
clearance between cover plate and housing . Remove
6. Remove cover plate, including shims, gasket, spring cover and select shim stack and new gasket to total
and yoke. Keep parts together. thickness of measured clearance plus 0.10-0.18 mm.
7. Remove steering pinion shaft seal. Check total thickness of shim and new gasket stack
8. Remove two bolts retaining steering pinion shaft lower with a micrometer then install shims between gasket
bearing cover plate. and housing. Replace yoke spring and torque cover
9. Remove cover plate, including shims, gasket, spacer, bolts to 17-21 Nm.
lower bearing and pinion shaft. Keep parts together. The above shimming method will give the required
10. Remove rack from housing. yoke clearance of 0.05-0.13 mm when a new gasket
is fitted and cover bolts torqued to specification .
11. Remove pinion shaft upper bearing .
12. Remove nylon rack bush from housing, if damaged. IMPORTANT: Once yoke clearance has been set and cover
bolts torqued to specification, gear must then be racked
from lock to lock to ensure localised wear has not ap-
CLEANING AND INSPECTION preciably affected setting, gear should not bind or appear
1. Wash all parts in cleaning solvent and blow off with air. tight over any part of the total travel. Should gear bind or
appear tight check shim stack and if not the cause, strip
2. Inspect both rubber boots thoroughly for damage and gear and examine rack and pinion for wear, replace if
deterioration. The boots are designed to prevent the necessary. The load required to rotate pinion at 12.7 em
entry of dirt and water, also retain the lubricant within radius applied as shown in Fig . 9-9 should not exceed
the steering gear. 2.3 kg (2.83 Nm torque) . Care should be taken when
3. Inspect pinion bearings for nicks, scores and signs of racking gear to avoid tooth damage at end of travel.
brinelling. Check balls thoroughly.
4. Check pinion for signs of tooth wear and tooth contact.
5. Check rack for signs of tooth wear, tooth contact and 11 . Fill cavity of pinion seal with graphite grease and install
signs of irregular wear pattern. Check for scoring at seal into housing.
yoke location and bushed section. 12. Install lock nuts on rack and screw beyond normal
6. Check steering gear housing bushing for scoring and locking position to allow room for adjustments of
wear. joints. Lubricate bearing surfaces of ball seats, joint
housing and tie rod seats with SAE 90 or EP 140 oil.
7. Check tie rod balls for signs of necking and wear. Assemble springs and ball seats, tie rods and ball
8. Check ball housings for signs of wear. housing to rack.
BALL HOUSING
""-- (~
'
' SEALING BOOT
~'
TIE ROD
PINION
~
INTERNAL LIP CAVITY TO BE FILLED ~---SHIMS&
WITH GRAPHITE GREASE PRIOR TO ASSEMBLY GASKET
SPRING
~ BEARING
SPACER ~~
YOKE COVER PLATE
'
~-""- YOKE
LOCK NUT
TIE ROD END ASSEMBLY
~
m
m
-::Dz
G')
0
(0
Figure 9-7 I
...1.
Manual Rack and Pinion Steering Gear ...1.
0
CD
I
......
1\)
~
PIN R~::KB~:: ~ ~
m
e
BALLSEAT m
~
BACKING DISC
~COIL THRUST SPRING HOUSING ASM
z
G)
BALL SOCKET ASM
OUTER CLIP
INNER WIRE CLIP

TIE ROD
CJ' PINION
t
~BALLRACE
SHIMS
~
0
SPACER
\
~ GASKET
COVER PLATE
4 SET SCREWS
Figure 9-7A
Exploded View of Manual Rack & Pinion Steering Gear
STEERING 09-13
£ 72 - 90Nm
& 44 - 55Nm
FOR CONNECTION TO
STEERING COLUMN
REFER FIG . 9-6
'
./~ \
\
I
/'"" v (4PLACES) "-'
,.....--.._
I
_/i
\
~NT OF CAR
".I
(2 PLACES)
Figure 9-8
Manual Steering Gear Installation
13. Adjust ball housing so that the tie rod will move when
a load of 1.8-3.7 kg is applied with a spring balance
at a distance of 20.2 em from the centreline of the tie
rod sphere. Note position of pin hole in rack and mark
position on ball housing .
14. Using special tools 9A38 and AU169 lock nut securely
against ball housing, recheck atticulation of tie rod .
15. After correct ball joint adjustment is achieved, note
position of original lock pin hole and torque lock nut
to 45-51 Nm . New hole in rack should not be within
90 degrees of original.
CAUTION: When torquing, use an adjustable wrench on flat
teeth of rack to prevent rotation and possible damage to
the rack or pinion teeth. Be careful not to nick or damage
rack on yoke side.
16. Tape rack to housing and ball housing to tie rod to
prevent metal chips entering.
17. Tape 5/ 32" drill at locking pin length, to avoid over-
drilling , and drill between lock nut and ball housing to
90 degrees to the rack and adjacent to lock nut notch.
Figure 9-9
NOTE: Only one redrill is advised for each locknut.
Checking Steering Gear Preload (Typical)
18. Place ball housing on wooden block, install lock pin
and stake housing and lock nut over pin. Clean off
chips and remove tape.
19. Assemble boot and clips to L.H. end of steering gear. INSTALLATION
Make sure tangs on clips will face downwards when 1. Slide steering gear shaft into coupling, aligning notch
steering gear is assembled on vehicle. in shaft with attaching bolt hole in coupling and torque
20 . Mount steering gear vertically in vice and pour 190- gear attaching bolts to 44-55 Nm .
210 mls of SAE 90 or EP 140 Gear Lubricant into 2. Install lower coupling and upper clamp bolts and
steering gear housing . torque to 12-16 Nm and 44-60 Nm respectively.
21 . Assemble boot and clips R.H . end of steering gear. 3. Install tie rod end to steering arms and torque nuts to
Make sure tangs on clips will face downwards when 72-90 Nm.
steering gear is assembled on vehicle. 4. Check toe-in and adjust if necessary.
09-14 STEERING
DIAGNOSIS GUIDE
This paragraph covers steering malfunctions which are c. Steering shaft coupling misalignment.
most likely to be caused by the steering gear assembly or d. Steering gear adjusted too tightly.
tie rods. e. Front wheel alignment incorrect.
1. Excessive play or looseness in steering system f. Steering column misalignment.
a. Front wheel bearings loosely adjusted . 3. Rattle or chuckle in steering gear.
b. Steering ball joints worn . a. Insufficient or improper lubricant in steering gear.
c. Steering wheel loose on shaft, loose tie rods, b. Loose or worn steering shaft bearings.
steering arms or steering linkage ball studs.
4. Poor returnability.
2. Hard steering - excessive effort required at steering
a. Steering gear adjusted too tightly.
wheel.
a. Low or uneven tyre pressure. b. Front wheel alignment incorrect.
b. Insufficient or improper lubricant in steering gear c. Insufficient or improper lubricant in steering gear
or steering ball joint. or steering ball joint.
d. Steering column misaligned .
SPECIAL TOOLS
9A39 Steering gear ball housing spanner.
AU169 Ball joint wrench - inner ball joint.
SPECIFICATIONS
Steering Gear Lube
Capacity ................................................................... 190-21 0 mi.
Type .............................................................. EP 140 or SAE 90
No. turns to lock to lock .................................................... 4.10
Rack travel (Total) ................................................... 143.26mm
Linkage
Type - Direct linkage from rack ends through the rods to
steering arms.
Tie Rod Ball Seat Friction .................. 1.8-3 .7kg at 20 .2cm
(from centre of tie rod sphere)
Yoke Support End Clearance ............................... .05-.13mm
Pinion Cover Clearance ......... ........................... .025-.076mm
Steering Gear Effort ...... ........ ............. 2.3kg max. at 12.7cm
(from pinion)

Steering gear to crossmember bolts ..... ............... 44-56Nm
Steering tie rod to steering arm nut ............ ... .. .... 72-90Nm
Ball housing lock nut .................................... .... ......... 45-51 Nm
Pinion or Yoke cover plate bolts ........................... 17-21 Nm
STEERING 09-15
POWER STEERING
INDEX
GENERAL DESCRIPTION ............................................... 09-15 POWER STEERING PUMP ............................................. 09-25
OPERATION ...................................................................... 09-17 REMOVAL .................................................................. 09-25
MINOR SERVICE OPERATIONS ................................... 09-17 INSTALLATION .......................................................... 09-25
DRIVE BELT ADJUSTMENT .......................................... 09-17 POWER STEERING PUMP PULLEY ..................... 09-28
FLUID LEVEL CHECK ..................................................... 09-17 Replacement ...................................................... 09-28
HYDRAULIC SYSTEM CHECK ...................................... 09-17 DIAGNOSIS ........................................................................ 09-28
TEST 1 -OIL CIRCUIT OPEN ................................ 09-19 SPECIFICATIONS ............................................................. 09-30
TEST 2- OIL CIRCUIT CLOSED ........................... 09-19 TORQUE WRENCH SPECIFICATIONS ........................ 09-30
FILLING & BLEEDING HYD SYSTEM .......................... 09-19 SPECIAL TOOLS .............................................................. 09-30
BLEEDING .................................................................. 09-19
MAJOR SERVICE OPERATIONS .................................. 09-20
POWER STEERING GEAR ............................................. 09-20
REMOVAL .................................................................. 09-20
INSTALLATION .......................................................... 09-20
DISASSEMBLY .......................................................... 09-20
INSPECTION .............................................................. 09-22
REASSEMBLY ........................................................... 09-22
GENERAL DESCRIPTION
The integral rack and pinion power steering gear Fig . 9-1 0 The mechanical portion of the steering gear contains its
uses a torsion bar and rotary valve and spool to direct and own supply of SAE 40 oil for lubrication and surplus oil is
control hydraulic pressure to the appropriate side of a transferred from one end of the rack assembly to the other,
power piston. The piston operates in a cylinder which is via an external by-pass tube between the boot seals when
integral with the rack assembly. Only slight relative rotation full lock is approached.
between the input shaft valve and spool is necessary to Should a hydraulic failure occur, the integral input shaft
introduce the hydraulic assistance. The hydraulic pressure and valve which is keyed to the pinion, operates the rack
assists the mechanical parts of the steering gear, which mechanically. The major hydraulic components of the
operate in a manner similar to the manual rack and pinion steering gear are the input shaft and valve, torsion bar,
steering. spool, rack and pinion assembly.
The rack is always immersed in fluid which helps absorb
road shocks as well as providing lubrication for the parts
of the hydraulic system .
0
(0
I
~
en
~
m
m
2:!
OIL BY PASS TUBE
FOR MECHANICAL SECTION ~ 8
z
RACK PISTON "
LEFT TURN RIGHT TURN

FEED TUBE FEED TUBE
TORSION BAR
VALVE
4 PORTSEATS
~ ) SPOOL
. • HOUSING
PART SECTION 'C'
W--- - - PISTON
VIEW ON ARROW 'B'
SECTION A-A
(Background Omitted)
Figure 9-10
Section View of Power Assisted Rack & Pinion Steering Gear.
STEERING 09-17
-PRESSURE
LEFT TURN
RIGHT TURN
TUBE /TUBE RETURN
/
POWER CYLINDER
I
RACK PISTON
Figure 9-11
Rack Right Turn Oil Circuit
OPERATION Fluid on the left hand side of the rack is forced back
through the left turn circumferential groove on the spool
Right Turn (Refer Fig . 9-12) - As the input shaft/Valve is opposing machined reliefs on the valve. The return reliefs
turned right, the torsion bar, connected between the pinion have holes which allow the fluid into the hollow centre of
and the input shaft/Valve, twists proportionally to the re- the valve . Holes higher in the valve direct the fluid to the
sistance of the vehicle road wheels . The amount of load upper portion of the spool, it then passes through the valve
applied to the torsion bar determines the pressure avail- housing and return line to the pump.(Fig. 9-13) .
able from the power steering pump. As the turning efforts on the torsion bar is eased, the valve
Fluid from the pump is directed through the valve housing is returned to its ne·utral position . Pressure on either side
into a circumferential groove on the spool, then through of the rack piston becomes equal and the self centreing
ports to opposing machined reliefs on the valve. The cir- effect of the steering assists in returning the steering gear
cumferential grooves on the spool are separated by Teflon to the straight ahead position.
seals. The relative rotation of the valve, directs the fluid Left Turn On the left turn, the torsion bar flexes
through ports into the right turn groove in the spool and and oil from the pump is directed via the valve to the left
through the housing into a feed pipe connected to the right turn groove in spool and to left hand side of rack piston.
hand side of the power cylinder. Return oil from the right side of the power cylinder enters
The fluid acts on the right hand side of the rack piston, the right turn groove and is returned to the power steering
which is fixed to the rack, and assists in moving the rack pump.
assembly to the right turn position. (Fig. 9-11 ).

DRIVE BELT ADJUSTMENT HYDRAULIC SYSTEM CHECKS
1. Loosen the pivot bolt and pump brace adjusting bolts. The following procedure outlines methods to identify and
isolate power steering hydraulic circuit difficulties. This test
CAUTION: Do not move pump by prying against reservoir is divided into two parts. Test number one provides a
or by pulling on pump filler neck. means of determining whether the power steering system
2. Move pump with belt in place until belt is tensioned to hydraulic parts are actually faulty.lf test number one results
125 plus or minus 5 for a new belt and 75 plus or minus in readings indicating faulty hydraulic operation, test
5 for a used belt using Tool No. 86208 strand tension number two will identify the faulty part. Before performing
gauge. Do not apply force to pump reservoir. hydraulic circuit test, carefully check belt tension, condition
of driving pulley and fluid level.
3. Tighten pump brace adjusting bolts and pivot bolt to
the values shown in 'Torque Wrench Specifications' . Engine must be at normal operating temperature. Inflate
front tyres to correct pressure. All tests are made with
FLUID LEVEL CHECK engine idling. Adjust engine idle to corrflct specification if
necessary.
1. Remove filler cap and check fluid level on dip stick When performing the two pressure checks it will be
with the fluid at operating temperature. necessary to connect pressure test assembly. Tool
2. Top up as necessary with * DEXRON II automatic No. 9A 7-1 into the line between the pump and steering
transmission fluid to bring level to the 'FULL' mark on gear. Tool No. 9A7-1 is used in conjunction with adaptor,
the dip stick. Tool No. 9A36 and hose 9A37. Refer Fig . 9-14.
0
CD
I
...a.
co
~
m
m
VALVE HOUSING
:2
z
C)
VALVE HOUSING TO RETURN SIDE

. . . . . OF POWER STEERING
PUMP.
VALVE SPOOL FROM PUMP VALVE SPOOL
TO RIGHT HAND
VALVE SPOOL RINGS (4) SIDE OF RACK
PISTON
FROM LEFT HAND SIDE
OF RACK PISTON.
'0' RING
·o· RING
INPUT GROOVE
RETURN
TO '---L........l'---- TO RETURN SIDE

RIGHT HAND - - - - ' FROM OF POWER STEERING
SIDE OF PUMP ,.-----,..--.--- PUMP
RACK PISTON
VALVE & TORSION BAR

VALVE & TORSION BAR
(SECTIONED)

Valve Right Turn Assist Pressure Valve Right Turn Return Oil Flow
STEERING 09-19
TEST 2 - OIL CIRCUIT CLOSED

a. Slowly turn valve to closed position, note pressure, and
quickly re-open valve to avoid pump damage.
TOOL No. 9A7-1 (i) If pressure was less than 6200 kPa (900 psi)
pump may be considered faulty.
(ii) If pressure was between 6200 kPa (900 psi) and
6890 kPa (1 OOOpsi), steering gear, external hoses
or connections may be considered faulty.
NOTE: If pump proves faulty, retest after overhaul to check
repairs and condition of steering gear.
FILLING AND BLEEDING HYDRAULIC

SYSTEM
During bleeding it is important to ensure that front wheels
, .,.__ _ TOOL No. 9A37 are off the ground and steering is not held forcibly against
HOSE TO PUMP EXISTING HOSE stops. Under loaded conditions, oil is injected into gear at
TO STEERING
GEAR . high pressure and if mixed with air not bled from system
will cause foaming . This will require 2-3 hours standing to
bleed out. After bleeding, fill reservoir to 'FULL' mark with
oil at 38 degrees -46 degrees C and with wheels straight
ahead . This temperature may be attained by moving
steering from lock to lock with wheels on the ground and
engine idling .
BLEEDING
1. Raise front wheels and with steering straight ahead
and stationary engine, fill reservoir with oil.
2. Move wheels from lock to lock and add fluid to
Figure 9-14
maintain level above pump body. Repeat until fluid
Pressure Test Assembly level remains constant.
3. With engine idling, operate steering from lock to lock,
LIGHTLY contacting stops and adding fluid to maintain
TEST 1 • OIL CIRCUIT OPEN level above pump body. System is bled when no air
bubbles are visible and level remains constant.
a. With valve open, start engine and with steering lightly
on full lock, check connections for leakage. 4. Fill reservoir to 'FULL' mark with oil hot and wheels
straight ahead as above.
b. Insert thermometer into reservoir filler opening and
move steering from lock to lock until fluid reaches If vehicle is to be steered for any length of time without
67-77 degrees C. engine running, fill reservoir only to just above pump body.
NOTE: To prevent scrubbing flat spots on tyres, do not turn REFILL TO CORRECT LEVEL WHEN NORMAL OPERA-
wheel more than five times without rolling car to change TION IS RESUMED.
tyre to floor contact area.
c. Turn steering to full lock momentarily, if pressure is
below 6200 kPa (900 psi) a faulty hydraulic circuit is
indicated.
09-20 STEERING

POWER STEERING GEAR 2. Remove tie rod ends and boots or cover boots to
prevent drill chips entering and drain oil.
REMOVAL 3. Drill out pin securing lock nut and ball housing to rack
using a 5/ 32" drill and remove right hand tie rod
1. Remove steering column flange and upper clamp assembly using special tools 9A38 and AU169 .
bolts. Care must be taken not to apply any force to
input shaft of gear. CAUTION: When removing ball housings, use an adjustable
2. Disconnect lines to steering gear, allow oil to drain and wrench on flat teeth of rack to prevent rotation and possible
tape or plug lines and pump connections to prevent damage to rack or pinion teeth. Be careful not to nick or
foreign matter entry. damage rack on yoke side.
3. Disconnect tie rod ends from steering arms using 4. Repeat procedure with opposite tie rod assembly.
suitable puller. 5. Remove cover plate, gasket, shims, coil thrust spring
4. Remove steering gear attaching bolts and withdraw and yoke support. Discard gasket.
assembly. 6. Remove pressure feed tubes.
7. Remove attaching bolts, wind valve housing assembly
INSTALLATION from rack housing and discard '0' ring seal.
1. Slide steering gear shaft into flange and install gear 8. Unscrew bush locknut from left hand end of housing
assembly to crossmember and torque attaching bolts using special tool No. AU 163. (Fig . 9-17)
to 44-56 Nm . Care must be taken not to apply any 9. Remove rack from left hand side of housing, taking
force to input shaft of gear. care not to damage housing tube with rack teeth or
2. Install clamp and flange bolts and torque upper clamp threads.
nut to 40-60 Nm then lower flange bolt, followed by 10. Remove bush bearing assembly from rack.
upper flange bolt, to 12-16 Nm . 11 . Remove piston ring and '0' ring from rack piston .
3. Install tie rod end into steering arms and torque nuts 12. Remove and discard '0' ring from bush bearing .
to 72-90 Nm. and fit split pins. 13. Support bush on wooden blocks and drive out seal
4. Connect lines to steering gear. from behind using small screw driver.
5. Refill pump reservoir and bleed assembly as outlined 14. Remove inner housing to rack seal using special Tool
under 'Filling and Bleeding the Hydraulic System'. No. AU164 by inserting tool into housing until it bot-
6. Check toe-in and adjust if necessary. toms 'fully' into seal, screwing bolt until seal is firmly
gripped and using slide hammer, part of 7A28, with-
DISASSEMBLY draw seal from housing . (Fig. 9- 18).
For identification of parts, refer Fig . 9-16.
1. Clean all dirt and foreign matter from exterior of NOTE: Before installing tool make sure that bolt is loosened
steering gear. fully and expander ball is not holding jaws open .
FOR CONNECTION TO
STEERING COLUMN
REFER SHEET 9A-3
FOR CONNECTION TO POWER

STEERING HOSES REFER
SHEETS 9-27 & 9-28
& 44-56Nm
Figure 9-15
Power Steering Gear & Coupling Assembly
SEAL
BUSH BEARING
ADAPTOR FLARE NUT

BUSH BEARING ASSY
'O'RING~
TORSION B A R 1
':t
BALL SOCKET ASSY PIN
SCREW VALVE HOUSING
PIMION & TORSION BAR ASSY \_
1
SPRING WASHER PORT SEALING SEAT
~
~
PINION
~
~BALL BEARING
~CIRCLIP
'0' RING
BACK UP WASHER
PINION HOUSING
PINION & SUPPORT
TIE ROD ASSY
OUTER CLIP
~
m
BALL SOCKET ASSY m
:!:!
z
C)
0
CD
Figure 9-16 I
N
Exploded View of Power Steering Assembly
"""
09-22 STEERING
15. Using a screwdriver, and a piece of plywood to protect

the pinion housing casting, pry the pinion seal from
housing.
16. Using suitable brass drift, knock out plug and lower
needle roller bearing from pinion housing if suspect.
17. Withdraw input shaft and valve assembly from valve
housing.
18. Pry out dust seal from top of valve housing .
19. Knock out upper needle roller bearing from valve
housing using suitable brass drift.
20. Using screwdriver, knock out upper valve housing seal.
21. If damaged, remove port seats from housing.
22. Remove thrust washer from input shaft.
23. Remove valve spool seal rings from spool.
NOTE: The input shaft, valve, pinion and torsion bar as-
sembly are serviced only as a balanced assembly and
should not be disassembled. Any attempt to disassemble Figure 9·17
and reassemble this balanced assembly will only result in Removing Locknut
an unbalanced assembly on completion.
INSPECTION
1. Inspect rack teeth, threads and piston for wear or parts, if found defective, will require the replacement of the
damage and seal surfaces for scoring. whole assembly.
2. Inspect ball housings, tie rods and seats for wear and
coil springs for damage. REASSEMBLY
3. Check bush bearing for wear or damage. During re-assembly, lubricate all seals, '0' rings and valve
4. Inspect needle roller bearings for wear or damage. and piston rings with Castrol LM greases or equivalent and
rack, pinion, pinion bearings and tie rods with SAE 40 oil.
5. Inspect yoke support and coil thrust spring for wear or
Cleanliness is most important, also take note of which
damage.
way seal lips are to be assembled.
6. Check rack housing tube and yoke support aperture
1. Install roller bearing to pinion and fit circlip. Care must
for wear or scoring .
be taken when assembling circlip so as not to damage
7. Inspect valve housing for wear or scoring and port seal diameter.
seats of damage.
NOTE: Bearing is a slight interference fit.
8. Inspect rubber sealing boots for tears or cracks .
2. Install seal rings onto spool carefully working them into
9. · Check input shaft splines for burrs. their grooves (It may be necessary to expand the teflon
10. Check input shaft, spool valve, pinion and torsion bar seals slightly by hand).
for wear or damage. 3. Install input shaft seal fully into valve housing, seal lip
NOTE: The input shaft, spool valve, pinion and torsion bar to the inside, using special Tool No. AU165.
are serviced as a balanced assembly and any of the above (Fig. 9-19)
TOOL No.
SEAL
4
3
Figure 9-18
Removing Inner Rack Seal
STEERING 09-23
TOOL No.
AU 165
VALVE
HOUSING
Figure 9-19
Installing Input Shaft Seal & Bearing
4. Using special Tool No. AU165, drive input shaft needle

roller bearing into valve housing until tool bottoms
(Fig. 9-19) . Figure 9-20
5. Install dust seal and port sealing seats into valve Installing Pinion Oil Seal
housing .
6. Fit thrust spacer over input shaft splines.
7. Wrap input shaft splines with PVC tape, to protect
housing seals, and install input shaft and valve as-
sembly into valve housing, working seal rings into
spool grooves and into valve housing with fingers.
8. Drive pinion needle roller bearing into pinion housing
until tool bottoms using special tool No. AU 165.
9. Apply sealer to plug and install into pinion housing until
flush with edge of housing. 14. Remove seal protector and screw ball housing lock nut
fully onto right hand end of rack, to prevent seal
CAUTION: A shift of plug below edge may dislodge needle
damage if rack is accidentally shifted back too far.
bearing, causing a foul on pinion.
15. Install seal into bush bearing, seal lip inwards, using
10. Install back up washer then pinion seal, lip upwards, special Tool No. AU166 and fit '0' ring into groove.
into rack housing using special Tool No. AU166.
(Fig. 9-20). 16. Install seal protector, special Tool No. AU168, over
rack thread and install bush bearing assembly over
11 . Install inner rack seal into housing, lip upwards (facing rack into housing (Fig. 9-23) and in bush bearing
tool), using special Tool No. AU166 (Fig. 9-21 ). locknut.
12. Fit '0' ring and piston ring into piston groove and fit
seal protector special Tool No. AU167 over rack teeth. NOTE: Take care that rack does not move back as bush
Fig. 9-22 . bearing and lock nut are installed .
17. Torque bush bearing lock nut to 108-163 Nm, using
NOTE: special tool No . AU163 , (Fig. 9-24) and screw ball
1. Do not overstretch Teflon ring when fitting . housing lock nut fully onto rack, to prevent seal
2. Smear LM Grease over seal protector for ease of damage if rack is shifted across too far.
assembly.
18. Fit '0' ring to valve housing and install assembly into
pinion housing taking care not to damage lower pinion
13. Place housing horizontally in vise and guide rack seal. Tighten attaching bolts to 34-41 Nm.
assembly carefully into housing, making sure that 19. Install oil feed tubes to housings, tighten securely and
piston ring fits into tapered portion of tube and push tape or plug remaining ports to prevent foreign matter
rack gently to the straight ahead position. entry (specially during later drilling operations) .
09-24 STEERING
TOOL NO. AU168
Figure 9-23
Installing Short Rack Seal Protector
Figure 9-24
Installing Locknut
Figure 9-21
Installing Inner Rack Seal
cover plate and select shim stack and new gasket to

total thickness of measured clearance plus 0.10-
0.18 mm. Check total thickness of shims and new
gasket stack with a micrometer then install shims
between gasket and housing . Replace yoke spring and
torque cover bolts to 16.5-20.5 Nm. Fig . 9-25 .
The above shimming method will give the required
yoke clearance of 0.05-0.13 mm when a new gasket
is fitted and cover bolts torqued to specification .
IMPORTANT: Once yoke clearance has been set and cover
bolts torqued to specification, gear must be racked from
lock to lock to ensure localised wear has not appreciably
affected setting, gear should not bind or appear tight, over
any part of the total travel. Should gear bind or appear tight
Figure 9-22 check shim stack, and if not the cause, strip gear and
Installing Long Inner Rack Seal Protector examine rack and pinion for wear, replace if necessary.
21 . Holding assembly in vise by mounting boss, assemble

spring, seat, tie rod and ball housing to rack. Tighten
20. With rack in straight ahead position, install yoke and ball housing, using special tool No. 9A38, until tie rod
cover. Do not fit yoke spring at this stage. Lightly will move when a load of 1.2-4 .3 kg is applied with a
tighten cover bolts, and with a feeler gauge, measure spring balance at a distance of 20.2 em from the
clearance between cover plate and housing . Remove centre line of the tie rod sphere.
STEERING 09-25
Figure 9-25
Checking Yoke Support End Clearings
22. Note position of original lock pin hole in rack and mark
on ball housing . Torque lock nut to 45-51 Nm and
recheck articulation of tie rod . (Fig. 9-26) .
CAUTION: When torquing, use an adjustable wrench on flat Figure 9-26

teeth of rack to prevent rack rotation and possible damage Torquing Lock Nut
to rack or pinion teeth. Be careful not to nick or damage
rack on yoke side.
23 . Tape rack to housing and ball housing to tie rod to

prevent metal chips entering. REMOVAL
24. Tape 5/32" drill at locking pin length, to avoid over 1. Disconnect hoses at pump, allow oil to drain in suitable
drilling, and drill between lock nut and ball housing at container and cap or tape pump and hose fittings to
90 degrees to the rack and within lock nut notch. prevent dirt entry. (Fig. 9-27-28).
NOTE: New lock pin hole should not be within 90 degrees 2. Loosen nut on rear bracket and remove bracket to
of original hole in rack and only one redrill is advised for head (V8) or block (L6) attaching bolt.
each lock nut. 3. Remove pump to bracket bolts and lower from bracket.
25. Place ball housing on wooden block install lock pin
and stake housing and lock nut over pin.
26. Repeat from step 26 on opposite end, clean off drilling INSTALLATION
chips and remove tape .
1. Install pump, fit attaching bolts loosely and connect
27. Assemble sealing boots, by-pass tube and clips, but
and tighten hose fittings.
before securing the housing end clips add 95 mls of
SAE 40 oil to each end of the housing. 2. Fill reservoir with DEXRON II and bleed by turning
pulley counter clockwise until bubbles stop. Top up
28. Secure clips to face downwards when steering gear is
level as necessary.
assembled on vehicle.
3. Fit and tension drive belt ot 125 plus or minus 5 NEW
or 75 plus or minus 5 USED. Tighten bolts and nuts.
CAUTION: DO NOT APPLY FORCE TO PUMP RESERVOIR

& DO NOT RUN PUMP WITHOUT OIL
POWER STEERING PUMP
NOTE: Drive belt tension is specified in strand tension as
For power steering pump operation and overhaul pro- measured by Warren and Brown Belt Tension Gauge Model
cedures refer to HQ Holden Service Manual Volume 2 and No. 982358. A belt is considered to be used after 1 0
specifications listed in this section. minutes running.
0
(0
I
1\)
0)
~
m
~- ~CLIP m
-z
lJ
' "'~ll C)
&
VIEW [6]
.1
RETURN
HOSE
&
I
POWER STEERING
PUMP
- PRESSURE HOSE
-ill
& 40 - 48 Nm
I '~
& 34-40Nm
& 3.4-4.6Nm
& 20-28Nm ~
& 20-28Nm
& 5.0-7 .5 Nm
Figure 9-27
Power Steering Pump & Hose Installation (L6))
& USE AS REQUIRED rnJ
POWER '
STEERING '
PUMP
r- jA
PRESSURE HOSE
VIEW[§]
& 40-48 Nm
CLIP
&
~
34-40Nm
& 3.4-4.6 Nm
& 20-28Nm
~ffU
PRESSURE LINE
II rA1
VIEW L.8J
0
CD
I
Figure 9-28 1\)
Power Steering Pump & Hose Installation (V8)) ......
09-28 STEERING
POWER STEERING PUMP PULLEY
Replacement
1. Remove power steering pump assembly as previously
outlined .
2. Using suitable press plates, support the pulley and
press pump assembly from pulley using a steel bar.
3. Refit pump to engine and nip up attaching bolts.
4. Make sure pulley bore is free of burrs, place pulley on
end of pump shaft (large boss to front) and install
replacer tool No. J25033 by screwing bolt fully into
pump shaft. Fig. 9-29.
5. Install pulley by holding large nut bearing and turning
bolt clockwise until nut bearng bottoms on pump shaft.
6. Tighten pump attaching bolts and nuts, adjust drive
belt and refill reservoir.
CAUTION: Take care to prevent burrs on pump shaft and

pulley bore. DO NOT HAMMER PULLEY AS THIS WILL
DAMAGE PUMP AND/OR PULLEY.
Figure 9-29
Installing Pulley
DIAGNOSIS GUIDE
Before proceeding with diagnosis, ensure that tyres are correct. Also check that general condition of suspension is
correct type and size for vehicle, inflation pressures are to satisfactory.
specifications and wheel alignment and fluid level are
Steering Wander
Cause Correction
Tie rod ball housing loose/worn. Adjust tie rod ball seat friction to specifications/ replace tie
rod ball housing and tie rod if worn .
Gear assembly loose on crossmember. Tighten mounting bolt nuts to specifications.
Loose pins in input shaft and valve assembly. Replace the input shaft and valve assembly.
Worn pinion bearing. Replace bearing.
Loose pinion ball bearing. Replace pinion ball bearing .
Worn bush bearing. Replace bush bearing.
Loose tie rod ends. Replace tie rod ends.
Excessive yoke support clearance. Adjust yoke clearance to specification.
Valve out of balance. Replace input/pinion/Valve assembly.
Rattle or Knocking Noises

Cause Correction
Loose/worn tie rod ball housing. Adjust tie rod articulation effort to specifications/ replace
tie rod ball housing and tie rod if worn .
Tie rod thrust bearing and coil spring broken or worn . Replace tie rod thrust bearing and coil spring .
Worn pinion shaft bearing. Replace pinion bearing.
Gear housing loose on crossmember. Tighten mounting bolt nuts to specifications.
Excessive yoke support clearance. Adjust yoke support preload to specifications.
Broken yoke support spring. Replace yoke support spring .
Worn yoke support. Replace yoke support.
Deteriorated front suspension . Strut insert. Replace strut insert.
STEERING 09-29
Heavy Steering
Cause Correction
Loose valve housing bolts causing leakage. Tighten valve housing bolts to specifications.
Leaking rack, pinion and/or input shaft seals. Replace rack seals, pinion seals, and/or input shaft seal.
Low steering system fluid level. Add steering fluid to proper level.
Bent rack assembly. Replace rack and piston assembly.
Damaged/worn teflon piston ring. Replace teflon piston ring .
Loose/missing rubber backup piston 0-ring. Replace/install rubber backup piston 0-ring.
Damaged pinion shaft bearing in the gear housing. Replace pinion bearing .
Rack bush bearing 0 -ring and/or oil seal leak. Replace 0-ring and/or oil seal.
Valve assembly internal leakage. Replace input shaft and valve assembly.
Valve Teflon 0 -rings cut or twisted . Replace Teflon 0-rings.
Yoke support preload excessive. Adjust to specification.
Piston disengaged from rack or improper depth of piston
ring groove. Replace rack assembly.
Gear housing oil seal leak. Replace gear housing oil seals.
Damaged gear housing tube. Replace gear housing.
Valve rings cut, twisted . Replace valve rings.
Rack piston ring cut, twisted . Replace rack piston ring .
Input shaft oil seal failure . Replace input shaft oil seal.
Leakage from loose pump hose fittings. Tighten hose fittings.
Misaligned steering column. Align Steering column .
Faulty power steering pump. Check power steering pump repair or replace as required .
Power steering pump belt slippage. Check and adjust belt tension .
Returnability Poor
Cause Correction
Binding in valve assembly. Replace input shaft and valve assembly.
Damaged / failed input shaft support bearing . Replace input shaft support bearing.
Loose/ Broken valve housing bolts. Torque valve housing bolts to specifications/replace.
Failed pinion bearing. Replace pinion bearing.
Misaligned steering column . Align steering column.
Binding tie rod ball housing. Replace as required.
Excessive lash in tie rod ends. Replace as required .
Binding in tie rod ball joints. Replace or adjust as required .
Bent or broken crossmember bending the rack. Inspect and replace as required .
Bent rack. Replace rack.
Broken gear housing . Replace gear housing.
Bent gear housing tube. Replace gear housing.
External Leakage
Cause Correction
Valve housing 0-ring. Replace 0-ring.
Torsion bar 0-ring. Replace input shaft/pinion/valve assembly.
Port seats or Unions. Replace or tighten unions.
Input shaft seal and dust seal. Replace seals.
Feed tubes loose or damaged . Tighten or replace.
Rack sealing boots damaged or clamps loose. Replace or tighten clamps.
Cover plate gasket. Replace gasket.
Tube to pinion housing 0-ring. Replace housing assembly.
09-30 STEERING
SPECIFICATIONS
Power Steering
Steering Gear Type - TRW rack and pinion with integral
power cylinder and rotary valve mechanism.
No. of Wheel Turns - Lock to Lock ................................ 3.21
Nominal Rack Travel (Total) ................................. 138.58mm
Pump - Make ................................................................. Saginaw
Pump - Type ........................................................ Vane Impeller
Pressure (at idle) ................ 6200-6890kpa (900-1 OOOpsi)
Drive ...................................................................................... Pulley
Lubrication type
Hydraulic ................................. DEXRON II Auto. Trans. Fluid
Mechanical ........................................................ SAE40 (190ml)
Drive Belt Tension
New belt ................................................... 125 plus or minus 5
Used belt ................................................... 75 plus or minus 5
Using Tool No. 8620B Strand Tension Gauge
Tie Rod Ball Seat Friction ............... 1.2 - 4.3kg at 20.2cm
(from centre tie rod sphere)
Yoke Support End Clearance ............................. 05 - .13mm

Nm
Steering Gear Attaching Bolts ...................................... 44-56
Tie Rod End to Steering Arm Nuts .............................. 72-90
Clamp Bolt .......................................................................... 44-60
Steering Coupling Flange Bolts .................................... 12-16
Bush Bearing Lock Nut .............................................. 108-163
Valve Housing Attaching Bolts ...................................... 34-41
Cover Plate Attaching Bolts ........................................... 17-21
Ball Housing Lock Nut .................................................... 45-51
Power Steering Pump

Nm
Bracket to pump pivot bolt ............................................ 20-28
Bracket to pump adjusting bolt .................................... 20-28
Pump bracket nut and bolt (L6) ................................... 20-28
Upper bracket to thermostat housing bolt (L6) ...... 20-28
Bracket to Timing case bolts (L6) ................................ 5-7.5
Bracket to thermostat housing bolts (L6) ................. 20-28
Bracket to cylinder head bolts (V8) ............................ 20-28
Pump bracket nut and bolt (V8) .................................. 20-28
SPECIAL TOOLS
AU163 ............................................................... Locknut Wrench
AU164 ....................................... Inner Housing Seal Remover
AU165 ....................................... Bearing and Seal Replacer -
Pinion and Input Shaft.
AU166 ........................ Seal Install - Pinion and Rack Seals.
AU167 .......................................... Rack Seal Protector (Long)
AU168 ......................................... Rack Seal Protector (Short)
AU 169 .......................... Ball Joint Wrench - Inner Ball Joint
WHEELS AND TYRES 10-01
SECTION 10
WHEELS AND TYRES
GENERAL DESCRIPTION .............................................. 10-01 TYRE AND WHEEL BALANCING ................................. 10-04
TYRES ................................................................................ 10-01 TYRE REMOVAL, REPLACEMENT AND REPAIR .... 10-04
WHEELS ............................................................................. 10-02 DIAGNOSIS ....................................................................... 10-04
SERVICE OPERATIONS ................................................. 10-03 LEAD ........................................................................... 10-06
INFLATION OF TYRES ................................................... 10-03 RADIAL TYRE LEAD DIAGNOSIS CHART ......... 10-06
WHEEL REMOVAL AND REPLACEMENT .................. 10-03 SPECIFICATIONS ............................................................. 10-07
ROTATION OF TYRES .................................................... 10-03 TORQUE WRENCH SPECIFICATIONS ........................ 10-07
WHEEL
TYRE OPTION
CAR MOOEL TYRE SIZE WHEEL SIZE OPTION REMARKS
NO.
NO.
CR 78 S14
OCR 14 X 6.00 JJ PC1 Base Option
4 P/R
COMMODORE & CR 70 H14 Minimum Specification

QCJ 14 X 6.00 JJ PC1
COMMODORE 'SL' 6 P/R Tyre with VS Engines
BR 60 H15 Available Option

QBC 15 X 6.00 JJ PH9
6 P/R
BR 60 H15 Base and only available

COMMODORE 'SLE' QBC 15 X 6.00 JJ PH9
6 P/R Option
ALL TYRES ARE OF STEEL BEL TED RADIAL CONSTRUCTION WITH BLACK SIDE WALLS.
PLY RATINGS ARE AS SHOWN
Figure 10-1
Tyre and Wheel Application Chart
GENERAL DESCRIPTION
TV RES
Steel belted radial tyres are used on all models. Com- option QCJ. These optional sizes are mandatory with VB
modore (BVK) and Commodore SL (BVL) are fitted with engines. No alternative tyre options are available on model
CR 78 s 14-4 ply rating OCR and Commodore SUE (BVX) BVX. Fig. 10-1 shows sizes and option numbers used.
with BR 60 H 15-6 ply rating tyres as the base option Tyre size designation is in accordance with tyre and rim
QBC. The BR 60 H 15- 6 P/R tyres are available on BVK association standards as follows:-
and BVL as option PH9/QBC and CR 70 H 14 6 P/R as
Load Capacity\ ~ Section. Rim

/ Proportions Diameter
C R 78 S 14 4 Ply Rating
~·~ ~Speed ~ Equivalent
~~~~~~u~ Rating
Load capacity is determined by size, aspect ratio and ply rating and shown on the sidewall as a load at maximum
inflation pressure e.g. 636 kg (1400 lbs) at 221 kPa (32 PSI).
10-02 WHEELS AND TYRES
WHEELS
6.00 JJ x 14 pressed steel wheels are used as standard small central cap pressed into the wheel. Conventional
fitment on 8VK & 8VL models and a 6.00 JJ x 15 cast alloy balance weights are used on steel wheel rim flanges but
wheel on 8VX model. All wheels are mounted on five 12mm special weights are required with a different clip for the
diameter studs. alloy rim.
Tyre and wheel sizes, inflation pressures and load capacity
All models are equipped with a spare tyre and wheel as-
are specified on a tyre placard located on the inside panel
sembly stowed in the luggage compartment (Fig. 10-2).
of the glove box door (Fig . 1 0-3) . Correct sizes and
8VK & 8VL models are fitted with wheel trim rings and pressures are the subject of a design rule and must be
central hub caps. On 8VX models the alloy wheels have a observed at all times.
_--------:~
SPARE WHEEL COVER
/
~·····' /
I I
1....-.J
Figure 10-2
Spare Wheel Stowage
NOMINATED
RIM SIZE
TYRE SIZE
DESIGNATION
MAXIMUM
TYRE LOAD
RATING
RECOMMENDED COLD INFLATION
PRESSURE -kPa ( P. S.l.) lYRE PLACARD
Kg (LB) UP TO 3 PASSENGERS UP TO MAX . LOAD
FRONT REAR FRONT REAR
6.00JJ CR78S14 558 (1230) 193 28) * 193 (28) * 221 . (32) * 221 (32) * WHERE SHOWN • 28kPa ( 4 P. S . l.) TO BE
6.00JJ CR70H14 599 (1320) 193 28 * 193 (28) * 221 (32) * 221 (32) * ADDED WHEN VEHICLE IS USED FOR
CONSISTENT HIGH SPEED OPERATION
&.OOJJ CR70H14 599 (1320) 193 28) * 193 _(28) * 221 . (32) * 221 (32) *
6.00JJ BR60H15 558 (1230) 193 (28) * 193 {28) * 221 (32) * 221 (32) * WARNING
WH'EN FITTED WITH WINTER TREAD lYRES, THIS VEHtCLE

SHOUlD NOT BE DRIVEN FOR PROLONGED PERIODS AT HIGH
SPEEDS.et. ABOVE tOitmlh. IUT NEVER AIOVE U!ikmn..
FOR ADOITIONAL INFORMATION REFER OWNER MANUAL

• TYRES MANDATORY WITH 910 TO 111Ut.
(lOGO TO 40011 1111 TRAILER PACKAGE .
VB 92004393
Figure 10-3
Tyre Placard
SERVICE OPERATIONS
INFLATION OF TYRES
The pressure recommended for any model is carefully
calculated to give satisfactory ride, stability, steering, tread
wear, tyre life and resistance to bruises.
Tyre pressure, with tyres cold (after car has stood for three
hours or more, or driven less than 2 kilometers) should be
checked weekly or before any extended trip, and set to the
specifications on the tyre placard located on the inside
panel of the glove compartment door. (Fig . 10-3) .
Valve caps or extensions should be replaced on the valves
to keep dust and water out.
Pressure Adjustments to suit operating conditions:-
NOTE: For continuous high speed operation, over
120 kmh, increase pressures 28 kPa or 4 psi up to the
maximum shown on the tyre placard.
Sustained speeds (above 120 kmh) are not recommended
when the 28 kPa adjustment would require pressures
greater than maximum recommended pressure shown on
the tyre placard .
Tyre pressure may increase as much as 40 kPa when hot.
DO NOT REDUCE PRESSURES TO COMPENSATE FOR
THIS BUILD UP.
For operation on unsealed rough roads, increase tyre
pressures 28 kPa COLD, DO NOT EXCEED pressures
shown on tyre placard. Where valve extensions are fitted, Figure 10-4
leave in position at all times. These extensions are self Wheel Nut Tightening Sequence
sealing.
NOTE: Clean valve extensions prior to applying pressure
line nozzle.
WHEEL REMOVAL & REPLACEMENT

Wheel removal is normally not difficult. If tight due to
corrosion do not use heat or heavy impact. Tighten and lF RF lF RF
then slacken each nut two turns and allow weight of car to
rest on wheel, rocking gently in forward and reverse gear
if necessary.
Before fitting wheels, ensure mounting surfaces are dry and
free of any build up of corrosion etc; even an unduly thick
film of paint can result in wheel nuts coming loose.
Wheel nuts must be carefully tightened to the appropriate
torque, shown in 'Torque Wrench Specifications' at the rear
of this section and in the sequence shown in Fig . 10-4.
lR RR lR RR
ROTATION OF TYRES
5 WHEEL ROTATION 4 WHEEL ROTATION
Rotation of tyres around the various positions on the
vehicle is normally only required to correct uneven wear
caused by some abnormal condition such as misalignment,
Figure 10-5
run-out or driving conditions . When such a condition is
evident the reason for it should be corrected if at all Tyre Rotation Sequence
possible. If it is expected to continue, for example in
conditions of constant hard cornering, rotation in ac-
cordance with Fig. 1 0-5 will assist in obtaining maximum
tyre life.
NOTE: As radial tyres are fitted, diagonal pattern rotation
is not recommended as roughness and irregular wear can
result and shoulder wear on front tyres is best equalized by
fitting to rear position on same side of vehicle.
10-04 WHEELS AND TVRES
TYRE AND WHEEL BALANCING Inflate tyre·to 275 kPa (40 psi) to seat tyre beads taking
care to avoid personal injury when the tyre bead snaps over
When tyre and wheel assemblies require balancing, they the safety hump.
should be removed from the car and balanced on a Never repair tyres worn below 1.5 mm tread depth .
machine capable of ensuring correct dynamic as well as
static balance. Balancing should be carried out in ac- Under no circumstances should a repair be attempted on
cordance with the machine manufacturers instructions to the sidewall of a tyre .
obtain the following results:- Repairs to radial tubeless tyres should be made only in the
Maximum allowable out of balance 3,6 kg mm central tread area between the major outside grooves, that
(5 inch ozs). is, no closer than 20 to 25 mm from the tread shoulders
depending on the tyre size.
When up to and including 85 grams, (3 ozs.) total weight
is used, this should be applied to the inside rim flange . DIAGNOSIS
When applying more than 85 grams (3 ozs), total weight,
split weights equally between inner and outer flanges. The most generally encountered tyre problems are:-
Difference between flanges should not exceed 15 grams Wear
(.5 ozs) with larger total weight on inside flange . Vibration
Maximum allowable total applied weight is 120 grams Lead
(4 .25 ozs) . Analysis of wear conditions is adequately covered in
Although hub and brake drums and discs do not contribute previous GMH Service Manuals and tyre company litera-
significantly to out of balance, it is desirable to refit wheels ture. Diagnosis of tyre and wheel conditions giving rise to
to same position on car after balancing. Before balancing vibrations is not so well covered and the following in-
remove all accumulated mud from wheel and any em- formation should be noted . The commonest cause of tyre
bedded stones from tyre treads. If using 'on car' balancing, and wheel vibrations is that of tyre imbalance and this is
equipment, (which will not generally give results equal to the first factor to be checked (refer 'Tyre and Wheel
that obtained on a balancing machine), observe precaut- Balancing' in this section).
ions in jacking car and protecting 'limited slip' differential If wheel and tyre assemblies are balanced to the degree
etc. required and vibration is still evident, then tyre run-out or
'Force Variation' could be responsible . (Refer Fig. 10-6) .
TYRE REMOVAL, REPLACEMENT AND Tyre run-out will always be present to some degree due to
REPAIR dimensional tolerances in both the tyre and the wheel and
can often be reduced by rotating the tyre on the wheel to
Whenever possible, tyre removal and replacement should cancel out the overall effect. The same problem can be
be carried out on a tyre changing machine. The use of tyre caused by 'Force Variation' which is in effect, a variation
levers and mallets is likely to damage tyre carcase and in stiffness around the tyre which results in a varying loaded
wheel rims. Minor dents and burrs on steel rims can be radius as the tyre rotates.
repaired by filing but alloy rims must always be replaced
if significantly damaged. All of these factors have so far been considered to act
radially. However lateral run-out and lateral force variation
CAUTION: Wheels must not be welded, brazed, peened or can also be translated into vehicle vibration ranging from
treated in any manner which could weaken them. low speed 'waddle' to relatively high speed shake or
vibrations similar to those obtained with tyre imbalance.
Use lubricant to GMH specification HN 1162 on tyre bead
The following diagnosis procedure indicates the process of
and rim flanges when mounting and de-mounting tyres. The
test and logic required to determine the cause of wheel and
bead seat of the rim must be clean and smooth; rust, rubber
tyre induced vibration .
etc., may be cleaned off with a wire brush.
If correct procedures for wheel balance have been carried
Before inflating tyre, rotate on rim to register balance mark
out and vibration is still evident the following procedure
on tyre in relation to valve.
should be followed:-
Check the locating rings on tyre sidewall to ensure that (a) Clean all foreign matter from wheel and tyre assem-
bead is properly seated and tyre is mounted concentrically blies including dirt or stones lodged in tread .
on wheel. Tyre run-out can easily result from careless tyre
mounting. (b) Demount tyres from wheels suspected as source of
vibration.
Details of materials and procedures for the repair of tyres
(c) Ensure the wheel disc and rim assembly is not bent or
should be obtained from the tyre manufacturer, however,
dented.
the following limitations should be observed:-
(d) Check wheel rim for radial run-out (Refer Fig.1 0-7) as
Tread punctures up to 6 mm diameter on radial tubeless outlined in Service Manuals. If radial run-out exceeds
tyres with steel bracing, must be repaired with a patch on specification, replace wheel assembly.
the inside of the casing in accordance with manufacturers
instructions. (e) Radial run-out on the road wheel should not exceed
0.90 mm (.035 in.) TIR for steel wheels and .05 mm
Before repairing the tyre, inspect the inner surface of the (.020 in.) TIR for alloy wheels, measured at the wheel
tyre casing to ensure there is no other internal damage rim bead seat: mark points of greatest (+) and least
which would affect the service life of the tyre. (-) radius. This can best be checked with the
Tyres which have had minor penetrations adequately re- wheel mounted on the balancing machine spindle.
paired by a vulcanising or chemical weld process are (f) If lateral run-out is evident or suspected (Refer
suitable for normal motoring but if they have had major Fig . 1 0-7) check at rim flange. This should not exceed
repairs they should not be used for speeds above those 1.14 mm (.045 in .) TIR for steel wheels and 0.70 mm
recommended for retread tyres. (.028 in.) TIR for alloy wheels.
SUSPENSION MOVEMENT
(Loaded Runout)
-----
----- - ----
SMOOTH ROAD
CAUSED BY
TYRE OUT TYRE RIM BENT

OF STIFFNESS OR
ROUND VARIATION OUT OF ROUND
Figure 10-6
Causes of Tyre and Wheel Induced Vibration
Tyre
A= Rad ial run-out (tyre)

B= Lateral run -out {tyre)
Wheel @--+
c = Lateral run-out (wheel)
D = Radi al run -out (bead seat)
E= Radial run -out (bead seat)
Figure 10-7
Run-Out Checking Locations
(g) With the tyre mounted on the rim, rotate the assembly LEAD
on the balancing machine spindle to measure run-out 'Lead' is the deviation of the car from a straight path on a
at the centre of the tyre tread . Total run-out should not level road (no camber) with no pressure on the steering
exceed 1.5 mm (.060 in .). If run-out exceeds this wheel.
figure, establish the points of greatest (+) and least
(- ) radius on tyre: mark the tyre at these locations. Lead is usually caused by alignment, brake drag etc., but
Deflate the tyre and rotate so the greatest radius area can sometimes be caused by tyres.
of the tyre is adjacent to the point of least radius on The way in which a tyre is built can produce lead in a car.
the road wheel. This should reduce total run-out to An example of this is placement of the belt in a radial tyre.
1.5 mm (.060 in.) or less. Off centre belts can cause the tyre to develop a side force
(h) When least run-out is achieved, (less than 1.5 mm while rolling straight down the road . If one side of the tyre
measured at tyre tread) re-balance wheel and tyre is a little larger diameter than the other, the tyre will tend
assembly: install to the vehicle and road test. If run-out 'to roll up' to one side. This will develop a side force which
limit cannot be attained replace wheel or tyre. can produce car lead . Before attempting to find a faulty
tyre, wheel alignment, brakes etc., should be thoroughly
(i) If the wheel-tyre assembly is still considered unac-
ceptable when road tested, replace the tyre and repeat checked.
procedure. The tyre removed should be returned to the The procedure in the 'Radial lyre Lead Diagnosis Chart'
tyre Manufacturer for investigation of its 'Force Vari - in this Section can be used to confirm lead due to a tyre.
ation' characteristics. By a process of elimination, if
balance and run-out are checked within these limits,
'Force Variation' i.e. variation in radial or lateral stif-
fness around the circumference of the tyre must be
responsible for any disturbance.
RADIAL TYRE LEAD DIAGNOSIS CHART
I INFLATETYRESTORECOMMENDEDPRESSURE I
I
ROAD TEST VEHICLE IN
BOTH DIRECTIONS
ON LEVEL UNCROWNED ROAD
NO WIND
I
SWITCH FRONT TYRES SIDE TO I
SIDE AND ROAD TEST AGAIN
I
I I
I LEADS IN SAME DIRECTION I I LEAD CORRECTED I LEADS IN OPPOSITE DIRECTION
I
PUT TYRES BACK IN ORIGINAL
I
LEAVE TYRES AS IS.
POSITION AND CHECK ALIGNMENT. INSTALL A KNOWN GOOD TYRE
IF ROUGHNESS RESULTS,
RECHECK FOR BINDING OR ON ONE FRONT SIDE
REPLACE FRONT TYRES
MIS-ADJUSTED STEERING
[
I LEAD CORRECTED
REPLACE TYRE
I LEAD REMAINS
INSTALL A KNOWN GOOD TYRE
IN PLACE OF OTHER FRONT TYRE
I I
LEAD CORRECTED I
1
LEAD REMAINS
CHECK TEST TYRES ON KNOWN
REPLACE TYRE GOOD CAR .
RECHECK ALIGNMENT
WHEELS AND TYRES

SPECIFICATIONS
WHEELS ..................................................................... 8VK & 8VL WHEELS ................................................................................... 8VX
Material .................................................................. Pressed Steel Material ......................................................................... Cast Alloy
Rim (Size & Flange) ............................................ 14 x 6.00 JJ Rim (Size & Flange) ............................................ 15 x 6.00 JJ
Offset (mm) ............................................. ................................... 43 Offset (mm) ................................................................................ 44
Attachment ............................................................................. Stud Attachment ............................................................................. Stud
Pitch Circle Dia. (mm) ......................................................... 120 Pitch Circle Dia. (mm) ......................................................... 120
Number & Size (mm) ........................................... 5 - 12 x 1.5 Number & Size (mm) ........................................... 5 - 12 x 1.5
TV RES
Size ..................... Refer Fig . 10-1 in this section for details
Inflation Pressure ............................................. Refer Fig . 1 0-3
in this section for details

Wheel Nuts ............................................................... Nm (lbs. ft.)
Pressed Steel Wheels ................................. 101-1 08 (75-80)
Cast Alloy Wheels ........................................ 1 01-1 08 (75-80)
NOTES
ELECTRICAL 12-01
SECTION 12
ELECTRICAL
Subject Page
BATTERY ........................................................................... 12.01
STARTING SYSTEM ........................................................ 12.01
GENERATING SYSTEM .................................................. 12.04
LIGHTING SYSTEM .......................................................... 12.05
INSTRUMENTS AND GAUGES ...................................... 12-15
RADIO-TAPE PLAYER .................................................... 12-35
WIRING HARNESS ........................................................... 12-47
WIRING DIAGRAMS ........................................................ 12-65
BATTERY SPECIFICATIONS
Make .............................................................. Lucas Or Chloride Seperater Material .. .................................................... Synthetic
Rated Voltage ............................................................................ 12 Case ................. ...................................................... Polypropylene
Number of Plates: Terminal Grounded ..................................................... Negative
L6 ....................... ............................................................................. 7 Electrolyte Specific Gravity:
VB ....................................... .......................................... 9 - 4.2 litre Fully Charged ...................................................... 1.240 - 1.260
VB .............................................................................. 11 - 5.0 litre Fully Discharged ................................................. 1.11 0 - 1.130
Capacity at 20 hours rating (min .): Bench Charging Rate ............................................ 4 - 6 amps
L6 ........................................ ................................. 4B (Red Cover) For details of battery tests and diagnosis guide refer to LC
VB ................................................ 61 - 4.2 litre (Yellow Cover) Shop Manual or HQ Service Manual, Volume 5, noting any
62 - 5.0 litre (Grey Cover) new specifications listed in this section.
STARTING SYSTEM
INDEX
GENERAL DESCRIPTION ............................................... 12-01 SPECIFICATIONS ............................................................. 12.03
BOSCH STARTER MOTOR ............................................ 12-03
BRUSH AND/OR SPRING REPLACEMENT ........ 12-03
GENERAL DESCRIPTION
'VB ' 'L6' engines are fitted with eith er Bosch or Lucas starter end frame and drive housing. These bearings require
motors, while VB engines are fitted with Bosch starter lubrication only at the time of overhaul.
motors. The basic operation , diagnosis, maintenance, The four brushes are supported by brush holders which are
testing and adjustment of both systems and overhaul retained to the commutator end frame by screws. Two
procedures are the same as for Holden HQ starter motors brushes are gounded to the frame and the other two are
and are fully covered in the Holden HQ Service Manual, insulated from the frame and connected to the field coils.
Volume 5, except for items and specifications listed in the The field coils are held in place by the pole shoes, which
following text. are attached to the starter frame by large diameter screws.
The Bosch starter motor (Fig. 12-1) and Lucas starter The field coils are connected to an insulated terminal on
motor consist of a motor, drive assembly shift lever and the starter frame, through which current is supplied to the
solenoid switch . The assembly is mounted on the upper motor.
left-hand side of the clutch housing on L6 engines. On VB Bosch starter motors have an armature brake assembly
engines the assembly is mounted on the rear left side of the which is an integral part of the drive assembly. The braking
cylinder case. The starter motor is a series parallel wound , effect of this assembly ensures a rapid return to rest of the
four-pole , four-brush type. armature after withdrawal of the pinion, thus reducing the
The armature shaft is supported at each end by oil- chances of re-engagement being effected with a rotating
absorbent sintered bushings pressed into the commutator pinion .
......
1\)
I
0
1\)
Olf~® ~ m
r-
m
Q
ll
0)>
r-
OJ©~0~4
BRUSH HOLDER ASSY"""
0=:\
'<:-:J
(:-';}_
~ ~~-HELICAL A~
COIL BRUSH \:JJV
(® ~
SPRING
OJ'\_
'\_ENGAGING LEVER
©©
DRIVE ASSY
\ \0~
I
~00 0"--- ARMATURE
SlEEVE
Figure 12-1
Starter Motor- Exploded View (Bosch)
ELECTRICAL 12-03
BOSCH STARTER MOTOR The brush springs are now helical coil type and the brushes
flat on the end to suit. Brushes should be replaced when
The Bosch starter motor differs from that described in the worn to a length of 12.7 mm .
Holden HQ Service Manual in that it incorporates a sleeve
on the armature shaft instead of a washer. In the rest
position the drive is held back against this sleeve. After the BRUSH AND/OR SPRING REPLACEMENT
starter has been disengaged, and the drive pinion is re- 1. Remove commutator end cover.
turned to its rest position, the solenoid plunger spring
2. Straighten retaining lugs and remove springs and
exerts force on the sleeve which forces the armature
towards the brush holder plate. This allows the moulded brushes.
ridge on the commutator to rub on the brush holder plate 3. Replace in reverse procedure.
acting as a brake. The armature has been modified to suit The V8 armature housing has been rotated lowering the
this new drive design . (Fig . 12-1 ). position of the solenoid .
SPECIFICATIONS
Engine L6 Engine va
Make .. ................... Bosch & Lucas - Four pole, Four brush Make ...................................... Bosch - Four-pole, Four-brush
Rotation (Drive End View) ...................................... Clockwise Rotation (Drive End View) ................................... Clockwise
Brush Spring Tension - Brush Spring Tension -
N (oz.) ................................................................................ 15 - 17 N (oz.) ................................................................................ 15 - 17
(54-61) (54-61)
Armature Shaft Bushings, Armature Shaft Bushings,
Drive and Commutator Ends ........................ Self-lubricating Drive and Commutator Ends ........................ Self-lubricating
End Play ................................................................. .05 - .03 mm End Play .................................................................. 05 - .03 mm
Lock Test - Lock Test-
Amps., max. (incl. solenoid ) ............................................... 51 0 Amps., max. (incl. solenoid ) ............................................... 51 0
Volts ................................................................................................ 7 Volts ................................................................................................ 7
Torque - Nm .............................................................................. 26 Torque - Nm .............................................................................. 26
Test Conditions ........................ Starter motor at ambient Test Conditions .......................... Starter motor at ambient
Motor Drive - Motor Drive -
Engagement Type Pinion Meshes ........ Solenoid actuated Engagement Type Pin ion Meshes ........ Solenoid actuated
(Front or Rear) ................................. screw push pinion shaft (Front or Rear) ..................................screw push pinion shaft
with over-running clutch Front with over-running clutch Front
No. of Teeth - No. of Teeth -
Pinion ............................................................................................. 9 Pinion ............................................................................................. 9
Flywheel ................................................................................... 137 Flywheel ................................................................................... 153
Solenoid Switch - Solenoid Switch -
Test Data - Test Data -
Solenoid 'Pull-in ' Voltage ..................................................... 6.0 Solenoid 'Pull-in' Voltage ..................................................... 6.0
(off Starter Motor) (off Starter Motor)
Solenoid 'Hold-in ' Voltage .................................... 05-.04 min Solenoid 'Hold -in ' Voltage .................................... 05-.04 min
(off Starter Motor) (off Starter Motor)
Solenoid 'Pull-in ' Current .................................................. 38.5 Solenoid 'Pull-i n' Current .................................................. 38.5
Solenoid 'Hold -in ' Current ................................................ 11 .0 Solenoid 'Hold-in' Current ................................................ 11 .0
12-04 ELECTRICAL
GENERATING SYSTEM
All VB L6 and 4.2 litre engines are fitted with Bosch or For Maintenance, Service, Testing and Diagnosis pro-
Lucas generators with 40 amp output as standard equip- cedures see LH Torana Service Manual or HQ Holden
ment. All 5.0 litre engines and air conditioned vehicles are Service Manual - Volume 5, noting any new specifications
fitted with either Bosch or Lucas 55 amp output listed in this section.
generators.
SPECIFICATIONS
Make ................................................ .................... Bosch or Lucas
Type ................ Diode Rectified 12 Pole, star wound stator
(including 3 separate excitor diodes)
Rating
Amps ................................................................................ 40 or 55
Volts ......... ............................................................ ......... 14 or 13.5
Ventilation ................................................................... Pulley Fan
Drive .................................................................................... 'V' Belt
Speed Ratio, Generator to .... ................ L6 Engi.ne - 2.36,
5
Crankshaft Revs. I ..................... VB Engme - 2.41
Rotor Shaft Bearings -
Slip Ring Erd .......................................................................... Ball
Drive End ................................................................................. Ball
Rotation ............................................... Clockwise at Drive End
Generator Output at Idle .............................................. 6 amps
Max. Continuous Output
Amps at Generator rpm .......... 40 at 6000 or 55 at 5.800
Voltage Regulator .................................................. Integral with
Generator
Type ........................................... .................................... Transistor
Voltage Setting ....................................... .................. 14.1 - 14.5
& 34-44 Nm ' (
,& 24-32 Nm
6 12-16 Nm
/1. 20-28 Nm
Figure 12·2
Generator Installation • Exc. Air Conditioning (For installation when A/C fitted, see Air Conditioning Section of this Manual)
ELECTRICAL 12-05
LIGHTING SYSTEM
INDEX
GENERAL INFORMATION .............................................. 12.05 GLOVE COMPARTMENT LAMP .................................... 12-11
HEAD AND PARK LAMP BULB .................................... 12.05 REPLACEMENT ......................................................... 12-11
REMOVAL .................................................................. 12.05 BOOT COMPARTMENT LAMP ...................................... 12-11
INSTALLATION .......................................................... 12.05 REPLACEMENT ......................................................... 12-11
TURN SIGNAL LAMP BULB .......................................... 12.05 DOOR COURTESY LAMP SWITCH .............................. 12-11
REPLACEMENT ......................................................... 12.05 REPLACEMENT ......................................................... 12-11
HEAD AND TURN SIGNAL LAMP ASSEMBLY ......... 12.08 BOOT COMPARTMENT LAMP SWITCH ..................... 12-11
REMOVAL .................................................................. 12.08 REPLACEMENT ......................................................... 12-11
DISASSEMBLY .......................................................... 12.08 GLOVE COMPARTMENT LAMP SWITCH ................... 12-11
REASSEMBLY ........................................................... 12.08 REPLACEMENT ......................................................... 12-11
INSTALLATION .......................................................... 12.08 LICENCE PLATE LAMP .................................................. 12-11
HEAD AND PARK LAMP SWITCH ............................... 12.08 REPLACEMENT ......................................................... 12-11
REMOVAL .................................................................. 12.08 ENGINE COMPARTMENT LAMP .................................. 12-11
CHECKING ................................................................. 12.09 REPLACEMENT ......................................................... 12-11
INSTALLATION .......................................................... 12.09 NEUTRAL START & BACK UP LAMP SWITCH ........ 12-11
INSTRUMENT ILLUMINATION RHEOSTAT ................. 12.09 STOP LAMP SWITCH ...................................................... 12-12
REMOVAL .................................................................. 12.09 REPLACEMENT ......................................................... 12-12
INSTALLATION .......................................................... 12.09 PARK BRAKE SWITCH ................................................... 12-12
INSTRUMENT PANEL ILLUMINATION REMOVAL .................................................................. 12-12
AND WARNING LAMPS ................................................. 12.09 INSTALLATION .......................................................... 12-12
BACK UP, STOP AND TAIL LAMP .............................. 12.09 HEADLAMP DIMMER CONTROL STALK,
BULB REPLACEMENT ............................................. 12.09 TURN SIGNAL & HAZARD WARNING SWITCH ....... 12-13
ASSEMBLY REPLACEMENT .................................. 12.09 REMOVAL .................................................................. 12-13
INTERIOR LAMPS - 8VX MODELS .............................. 12.09 INSTALLATION .......................................................... 12-13
INTERIOR LAMP- 8VK & 8VL MODELS .................... 12.09 HAZARD WARNING FLASHER ..................................... 12-13
REPLACEMENT ......................................................... 12.09 SPECIFICATIONS ............................................................. 12-14
GENERAL INFORMATION
Rectangular multi-contruction quartz halogen headlamps INSTALLATION
are standard on all VB models. The front park lamp bulb 1. Locate new headlamp bulb in reflector (one way fit) or
is attached to the headlamp bulb holder and protrudes park lamp bulb in holder.
through a slot in the reflector. Front turn signal lamps are
2. Replace holder, locating park lamp bulb in slot in
slotted onto the headlamp housing and are secured by
reflector.
spring clips.
3. Refit connector and replace cap noting 'Top' mark.
All models are fitted with a stalk control for operation of
headlamp dimmer, turn signal, windshield wiper and NOTE: Quartz envelope of headlamp bulb must not be
washer. A four way hazard warning system is also in- handled . If touched accidently, wipe immediately with
corporated in the turn signal switch . methylated spirits otherwise bulb performance may be
affected.
HEAD & PARK LAMP BULB

REMOVAL TURN SIGNAL LAMP BULB
1. Remove cap , rotate counter-clockwise Fig . 12-3.
2. Remove connector from headlamp bulb (if being re- REPLACEMENT
placed) , turn bulb holder counter-clockwise and re- 1. Twist bulb holder counter-clockwise, remove and re-
move from reflector. place bulb.
3. Replace bulb / s as necessary. 2. Re-install in reverse.
..A.
1\)
I
0
0')
m
r
/
/
m
/
Q
/
/ ::D
~
HEADLAMP BULB
AFTER INSTALLATION OF HARNESS

PRESS GROMMET INTO LAMP HOUSING
SECURELY.
~ FRONT OF CAR
t -r ~""' ;s:: VIOLET LEAD
---CAP
TURN SIGNAL
BULB
.'~
·'· t-t:::
"·~
, .t', \
:r.r_-.;..<;
MAIN WIRING HARNESS
L. SIDE SHOWN
Figure 12·3
Headlamp, Turn & Park Lamp Bulb & Harness Installation
ELECTRICAL 12-07
GASKET
REFLECTOR
~CAP
~- - ~1~,- ~~
~ HEADLAMP BULB
+-VERTICAL
ADJUSTER
-HORIZONTAL ADJUSTER
. -·j
v .
_______;t--iL_ ADJUSTING LEVER
Figure 12-4
Headlamp Assembly
12-08 ELECTRICAL
HEAD & TURN SIGNAL LAMP ASSEMBLY REASSEMBLY

1. Start horizontal adjuster into nut with lever down and
REMOVAL out of seat.
1. Remove grille and lower headlamp moulding . 2. Fit reflector into retaining hole and slot and push lever
up to engage reflector rubber support.
2. Disconnect main wiring harness plug Fig. 12-3.
3. Reassemble remaining parts in reverse to disassembly.
3. Remove two top headlamp retaining screws.
4. Lift assembly from the bottom , out of the plastic re- INSTALLATION
taining clamps and pull outwards.
1. Check that plastic retaining clamps are in position .
NOTE: Assembly may be firm fit, take care when releasing 2. Feed top mounting tangs of headlamp assembly over
from plastic retainers . mounting holes in front end panel and start attaching
screws.
DISASSEMBLY (Fig. 12-4)
3. Push bottom of assembly into retainers and tighten
1. Disconnect turn signal lamp holder. mounting screws.
2. Compress and remove spring clips retaining turn 4. Reconnect harness plug .
signal lamp and slide lamp forward and over tangs .
5. Replace grille and lower headlamp moulding.
3. Pry clips retaining lens to housing and remove lens and
gasket. NOTE: If reflector has been removed, headlamp aim will
need to be checked see Fig . 12-5.
4. Remove cap (rotate counter-clockwise) and discon -
nect head and park lamp connectors, rotate bulb
holder counter-clockwise to remove and remove
bulbs. HEAD & PARK LAMP SWITCH
5. Unscrew horizontal and vertical aligning screws from
reflector and adjusting lever. REMOVAL
6. Remove plastic retainer holding link to housing and 1. Pry switch, which is a snap fit, forward from dash .
remove reflector from housing . Fig . 12-6.
NORMAL AIMING POINTS CHECKING LIMITS

...J 1- 1- 1-
<1: 1- ~
v 1- ~ ~ ~
z ...J
<1: v ~
...J ...J :::i
OCJ UCJ
Nzt- 1-_z
-zr-
:::i:i'
1- ~--~ a:5' ~~
a:-z a:~-
o~o
J:<l:o..
UJ-O
><to..
- 'r-HL
u.
UJ
...J
J:
C)
a:
UJ
0..
0..
:::l
~
0
...J
H~
VD r- rHR
r
V////j/H
V///// + ' H
~FF
~AI
--<...<., Ul
v1tJ E E E
z E
LINE MIN:
X
<1: ~ E v2 E
0
0
0
E Ln
E
O.n 0 N
POINT Or-- CUT OFF LINE Ln ~
> ~
v MUST BE WITHIN
THIS ZONE
EUROPEAN BEAM
1. HEADLAMP AIMING IS TO BE PERFORMED WITH THE VEHICLE

INCORPORATING OIL, WATER & 4.4 LITRES OF PETROL
TYRES MUST BE INFLATED TO CORRECT PRESSURES. C VEHICLE
VERTICAL VERTICAL C
2. ADJUSTMENTS TO BE MADE WITH CAR AT 76 METRES C LH RH LAMP
DISTANCE FROM SCREEN OR THE PROPER DISTANCE FROM
OTHER INSPECTION EQUIPMENT WHICH GIVES ESSENTIALLY LAMP , ,v VI HORIZONTAL
!=l===t====~====~j~~C~JS
EQUIVALENT OR MORE ACCURATE RESULTS .
3. CAR AND SCREEN ARE TO BE SET ON A LEVEL FLOOR

WITH HORIZONTIAL AND VERTICAL CENTER LINES OF LAMPS AND
CAR CORRECTLY INDICATED ON T HE TEST SCREEN .
/ / / / / / / / / / / / / / / / / / / ' / / / FLOOR
4. EACH LAMP IS TO BE CHECKED INDEPENDENTLY ON LOW BEAM
5. FOR EACH PAIR OF LAMPS THE MAXIMUM ALLOWABLE VARIATION

L MAXIMUM ALLOWABLE VERTICAL
VARIATION 50 mm (20 in)
IN THE VERTICAL LOCATION OF AIMING POINTS IS 50 mm (2.0m)
Figure 12-5
Headlamp Aiming Chart
ELECTRICAL 12-09
INSTRUMENT PANEL
LOWER
INSTRUMENT
ILLUMINATION
RHEOSTAT
SECTION B- B
SCREWS & Figure 12-7
Rear Lamp Assembly
2 PLACES
2. Remove wiring connectors from rheostat.
~ ~.INSTRUMENT PANEL 3. Remove attaching screws and withdraw rheostat from

behind dash.
~- ~~ LOWER
INSTALLATION
1 . Reverse removal operations.
INSTRUMENT PANEL ILLUMINATION &

WARNING LAMPS
HEAD & PARK Instrument illumination and warning lamp bulbs are a push
LAMP SWITCH
fit into holders which twist-in to the rear of the combined
instrument assembly.
BACK-UP, STOP & TAIL LAMP

Figure 12-6 BULB REPLACEMENT
Head & Park Lamp Switch & Instrument Illumination Rheostat 1. Spread detent springs and withdraw socket assembly
and remove bulb/s Fig. 12-7.
2. Remove wiring connectors from switch. (At this stage
the switch illumination bulb may be withdrawn and ASSEMBLY REPLACEMENT
replaced.) 1. Disconnect wiring harness from socket assembly.
2. Remove screws attaching assembly to rear end panel.
CHECKING
Test resistance between terminals or use jumper lead
from a live wire to appropriate terminal of switch. INTERIOR LAMPS - 8VX MODELS
If no change in light brilliance is noted, the switch For bulb, dome and quarter lamp replacement see
contacts are satisfactory and the defect is in the circuit. Fig. 12-8.
INSTALLATION
1. Reverse removal operations making sure that switch is INTERIOR LAMP - 8VK & 8VL MODELS
pushed home until latch engages.
REPLACEMENT
1. Remove fuse for interior lamp (No. 2).
INSTRUMENT ILLUMINATION RHEOSTAT 2. Pry out from LH side of assembly, withdraw assembly
and remove connectors . Replace bulb if necessary.
REMOVAL 3. Replace connectors, feed assembly into RH side of
1. Remove head and park lamp switch as above hole and snap into place.
Fig. 12-6. 4. Replace interior light fuse.
......
1\)
I
NOTE: REMOVE INTERIOR LAMP FUSE
BEFORE REMOVAL OF ASSEMBLIE:S
LEAD TO BE TAUT
BETWEEN CLIPS
......
TO PREVENT SHORTING OF TERMINALS 0
m
r
m
Q
:a
~
r
REAR QUARTER LAMP AND WIRING R.H. SIDE
LEAD TO
DOME LAMP 1.....------ MATCH LEAD COLOURS
WHITE TO WHITE HOUSING~
ORANGE TO ORANGE
LEAD FROM R.H.

R.R. QUARTER
LAMP
REAR QUARTER LAMP WIRING L.H. SIDE
LENS
DOME LAMP
& 2,4-3,4 Nm
Figure 12-8
Interior Lamps Installation - 8VX Models
ELECTRICAL 12-11
r BROWN LEAD
BLACK LEAD
1.. SWITCH
L LAMP
Figure 12-9
Boot Compartment Lamp & Switch
GLOVE COMPARTMENT LAMP
REPLACEMENT _....... LICENCE PLATE LAMP

1. As above, but not necessary to remove fuse.
BOOT COMPARTMENT LAMP
REPLACEMENT
1. As above except, remove connector from switch to
prevent terminals shorting on apature and pry lamp
from rear most end first (Fig. 12-9) .
DOOR COURTESY LAMP SWITCH

VIEW [8J
REPLACEMENT
1. Remove retaining screw, pull switch through appature Figure 12-10
and disconnect wiring harness plug. Licence Plate Lamp
BOOT COMPARTMENT LAMP SWITCH
REPLACEMENT
1. As above, from LH hinge support. (Fig. 12-9).
ENGINE COMPARTMENT LAMP
GLOVE COMPARTMENT LAMP SWITCH REPLACEMENT
1. Check that park and/or headlamps are switched off.
REPLACEMENT 2. Pry lamp out from passenger side of bonnet first.
1. Pry out switch which is snap fit and disconnect wiring Replace bulb if necessary, Fig. 1 2-11.
harness plug. 3. Disconnect wiring harness connectors.
2. Reverse removal operations. 4. Reverse removal operations.
LICENCE PLATE LAMP

NEUTRAL START & BACK UP LAMP
REPLACEMENT SWITCH
1. Pry lamp, which is a snap fit , from bumper and dis- No switch adjustment is necessary on any trans-
connect lead, Fig . 12-1 0. missions. For removal procedures of switches refer
2. Unclip lens assembly from base. Transmission Section.
12-12 ELECTRICAL
GROMMET
I I
Figure 12-11
Engine Compartment Lamp
STOP LAMP SWITCH

PARKBRAKE WARNING LAMP
LEAD FOR CONNECTION
j
REPLACEMENT REFER FIG. 12-49 \
1. Disconnect electrical connectors from switch. \ RUBBER SILENCER
;~~CES
2. Remove switch from bracket.
3. Reverse removal operations, screwing switch in until _, 1
brake lights operate when pedal is depressed 15 -
16 mm. \ 4
PARK BRAKE SWITCH "--~~

~' ~/ t
RETAIN UNDER ».
EXISTINGCLIP ..,d_,y
REMOVAL II
1. Disconnect park brake cable from relay rod.
2. Remove console and lift carpet to gain access to
handle mounting bolts on left hand side.
3. Remove bolts, lift out lever assembly and remove
switch from lever assembly.
4. Disconnect yellow lead from under dash and feed out
from under carpet and through grommet. (Fig . 12-12).
INSTALLATION
1. Reverse removal operations, tape lead to floor pan and
torque lever attaching bolts to 20 - 25 Nm. Figure 12-12
2. Adjust park brake cable as outlined in Section 5. Park Brake Switch and Lead Routing
ELECTRICAL 12-13
HEADLAMP DIMMER CONTROL STALK, HAZARD WARNING FLASHER

TURN SIGNAL & HAZARD WARNING The traffic hazard flasher has been integrated into the
SWITCH steering column with a control button located on the
direction signal switch housing. Pushing the button causes
REMOVAL (Fig. 12-13) both the right and left hand direction signals to blink
1. Disconnect battery ground cable . simultaneously.
2. Remove horn bar. The switch may be disengaged by pulling out the button on
3. Remove steering wheel using tool No. 9A-1 and two the steering column. Unlike the direction signal flasher, the
M8 x 1.25 x 7 6 mm bolts. traffic hazard flasher is the variable load type and will
operate regardless of the number of bulbs which are op-
4. Disconnect and unclip wiring harnesses. erative. The flasher assembly is located on the fuse block.
5. Unscrew hazard warning knob from turn signal switch.
To replace hazard warning switch follow removal operat-
6. Remove screws retaining control stalk and switch ions as outlined above.
assembly and remove units, feed harness through
shroud. If front or rear lights fail to operate, check appropriate
system for open circuit or blown bulbs.
INSTALLATION If complete system does not operate check for blown fuse
1. Replace in reverse order torqueing steering wheel nut (same circuit as horn and dome lamp) loose connections ,
to 19- 20 Nm and lock nut fingertight plus 1I 4 - 1/ 3 or open circuit. If new fuse blows check for short in circuit.
turn .
WIPER/WASHER ASSEMBLE SUPPORT ASM.

AND HEADLAMP WITH CAMS IN THIS
DIMMER CONTROL 1
POSITION
VIEW IN DIRECTI ON O F
ARROW
ASSEMBLE THRU
STEERING COLUMN
HOUSING & SELF TAP
INTO PLASTIC SUPPORT
OF SWITCH
FOR CONNECTION TO MAIN

WIRING HARNESS REF. FIG. 12-49
COAT ELECTRICAL
CONTACT SURFACE
WITH HN1346
SECTION A- A
fl'::. 19 - 22 Nm
SECTION 8 - B
ffi 2 - 2 .5 Nm
Figure 12-13
Wiper/ Washer & Headlamp Dimmer Control Stalk & Hazard Warning / Turn Signal Switch Installation
12-14 ELECTRICAL
SPECIFICATIONS
Turn Signal Flasher Unit All Switch & Control Illumination
Make ................................................................ .... .............. ..... Hella Generator Charge Indicator ............................................ 2 c.p.
Operati on ...... .... ... ... ..... ................ 60 / 120 flashes per minute Back Up & Turn Signal Lamps .... ............. 21 watt Bayonet
with audible sound Domelamp .. ................ .................... ............ .. 15 watt Festoon
Locati on ......................................................... ..... ..... ... Fuse panel Engine & Rear Compartment ..................... 1 0 watt Festoon
Hazard Warning Flasher Unit Dome Lamp - 8VX ......................................... 1 2 watt Festoon
Make ......... .... .................................... .... ....... ...... ........... .... .. ... Delco Reading Lamp - 8VX .................................... 15 watt Bayonet
Operation ......................... ........ .. .. 60 / 120 flashes per minute Interior Rear Quarter Lamps -8VX .............. 5 watt Festoon
Location ...................................................................... Fuse panel Front Park Lamp .......................... .................... 4 watt Bayonet
Rating of Bulbs Glove Box Lamp ................ .. .. .. ......................... 5 watt Festoon
Headlamp .. ........ ........................................ 60 / 55 watt halogen Licence Plate Lamp .. .................................... 1 0 watt Bayonet
Instrument Panel Illumination .............. .. .... . 1.2 watt push -in Stop / Tail Lamp ................... ...................... 25 / 6 watt Bayonet
ELECTRICAL 12-15
INSTRUMENTS & GAUGES

INDEX
GENERAL DESCRIPTION ............................................... 12-15 WINDSHIELD WIPER & WASHER ASSEMBLY ......... 12-24
INSTRUMENT ASSEMBLY ............................................. 12-17 GENERAL DESCRIPTION ....................................... 12-24
REMOVAL .................................................................. 12-17 WIPER ARM ............................................................... 12-24
INSTALLATION .......................................................... 12-17 Replacement ...................................................... 12-24
DISASSEMBLY .......................................................... 12-17 WIPER MOTOR & LINKAGE .................................. 12-24
Speedometer, Fuel Consumption Removal .............................................................. 12-24
Indicator & Tachometer ................................... 12-17 Installation .......................................................... 12-24
Fuel & Temperature Gauges .......................... 12-17 WINDSCREEN WIPER/WASHER CONTROL
Voltmeter & Oil Pressure Gauge ................... 12-17 STALK ......................................................................... 12-29
Printed Circuit .................................................... 12-17 Removal .............................................................. 12-29
ASSEMBLY ................................................................. 12-17 Installation .......................................................... 12-29
SPEEDOMETER ................................................................ 12-17 DWELL CONTROL SWITCH ................................... 12-29
SPEEDOMETER CABLE ................................................. 12-17 Removal .............................................................. 12-29
INSPECTION OF CABLES ...................................... 12-17 Installation .......................................................... 12-29
GENERATOR WARNING LAMP .................................... 12-20 WINDSHIELD WASHER PUMP .............................. 12-29
OIL PRESSURE WARNING LAMP ................................ 12-20 Replacement ...................................................... 12-29
BRAKE WARNING LAMP ............................................... 12-20 WASHER RESERVOIR ............................................ 12-29
PARK BRAKE WARNING LAMP .................................. 12-20 Replacement ...................................................... 12-29
VOLTMETER ..................................................................... 12-20 WASHER NOZZLE ................................................... 12-29
TACHOMETER .................................................................. 12-20 HEADLAMP WIPER/WASHERS •.................................. 12-29
FUEL, OIL & TEMPERATURE GAUGE ........................ 12-20 GENERAL DESCRIPTION ....................................... 12-29
FUEL GAUGE SENDER UNIT ........................................ 12-21 HEADLAMP WIPER ARM ........................................ 12-29
TEMPERATURE SENDER UNIT .................................... 12-21 Replacement ...................................................... 12-29
OIL PRESSURE SENDER UNIT .................................... 12-21 HEADLAMP WIPER MOTOR .................................. 12-29
FUEL CONSUMPTION INDICATOR .............................. 12-21 Removal .............................................................. 12-29
CLOCK ............................................................................... 12-24 Installation .......................................................... 12-29
HORN .................................................................................. 12-24 TIMER .......................................................................... 12-29
VOLTAGE TEST AT HORN .................................... 12-24 WASHER SOLENOID VALVE ................................ 12-30
HORN ADJUSTMENT ............................................... 12-24 WASHER NOZZLE ................................................... 12-30
HORN ACTUATOR ................................................... 12-24 CIGAR LIGHTER ............................................................... 12-30
SPECIFICATIONS ............................................................. 12-30
GENERAL DESCRIPTION
The combined instrument assembly as fitted to 8VK models On 8VL models the assembly is the same except for the
incorporates a 200 kph speedometer, fuel consumption addition of an oil pressure gauge and voltmeter. The oil
indicator, temperature and fuel gauges. The assembly also pressure indicator lamp is replaced with the Holden lion
incorporates turn indicator/ hazard warning lamps, high emblem .
beam indicator, generator, park brake engaged, brake The 8VX model instrument assembly is the same as 8VL
system failure , oil pressure warning lamps. A trailer warning except that th e fuel consumption indicator is replaced by
lamp lens is provided and with the approved GMP & A a tachometer.
trailer harness kit installed , it moniters the turn signal
operation .
......
1\)
I
......
0)
/f_ I FRAM E AS M m
r-
m
. ~~~
-~~
~- 0"·";;;::~--- -~~
~
lJ
~r-
/''~~t~~ . ).,
/~----~~'.\
', \~--/
--:---/
/ ( \ /~
,/_....::~
- -®
~~~~-
-
--~~~~/-:11 -r-- I I '
.,
'
\1 _ - -
A
//\ Iffi )kl i
)
COMBINED INSTRUMENT ASSEMBLY
I
,:) .-~ v
~ /1/ I
3 PLACES
SECTION A-A FOR INSTRUMENT WIRING REFER FIG . 12-49 & 49(a)
Figure 12-14
Instrument Carrier & Frame
ELECTRICAL 12-17
INSTRUMENT ASSEMBLY Printed Circuit

1. Remove all twist-in holders.
REMOVAL 2. Compress and withdraw retaining clip / heat sink and
1. Disconnect battery. voltage stabilizer assembly from housing (Fig. 12-16).
2. From under dash disconnect hose to fuel consumption 3. Slide printed circuit to right and lift out.
indicator or tachometer lead, where fitted .
3. Disconnect speedometer cable by depressing the ASSEMBLY
spring retainer. 1. Reverse removal operations.
4. Remove screw retaining the frame and withdraw frame. 2. Install retaining clip/heat sink ensuring voltage
(Fig . 12-14) . stabilizer contacts locate properly.
5. Remove three screws retaining instrument assembly 3. Install upper gauges first (where fitted) ensuring gauge
and laying assembly on its back, withdraw far enough contacts are properly located .
to disconnect multi wiring harness connector, volt-
meter and oil pressure gauge connector where fitted .
6. Withdraw assembly from left hand side depressing
speedometer retainer to clear dash pad .
INSTALLATION
1. Reverse removal operations ensuring that connectors
and speedometer cable are fully installed.
DISASSEMBLY
Remove two screws retaining facia, unhook tangs from
assembly and remove facia .
Speedometer, Fuel Consumption Indicator &

Tachometer
1. Remove two screws retaining unit and withdraw unit.
When removing tachometer, carefully withdraw con-
tacts from printed circuit.
Fuel & Temperature Gauges

Figure 12-16
1. Remove gauge retaining screw 'A' (Fig . 12-15)
Voltage Stabilizer & Heat Sink
2. Compress plastic retaining tang ' B' (Fig . 12- 15) and
withdraw gauge contacts from printed circuit.
Voltmeter & Oil Pressure Gauge

1. Remove overlapping fuel or temperature gauge as SPEEDOMETER
previously outlined . Speedometer cable breakage or wavering of the pointer
2. Remove remaining retaining screw and withdraw may be caused by a binding in the speedometer head or
gauge contacts from printed circuit. a kink in the speedometer cable casing.
To test the speedometer for a binding condition, cut ap-
proximately 76 mm off a broken or disused speedometer
cable, leaving the tip that fits the head intact. Remove the
instrument panel as previously outlined and insert the piece
of cable into the speedometer head . Spin the test cable
three or four turns and if any tendency to bind is felt the
head should be removed for repairs .
Servicing of the speedometer assembly should only be
carried out by an authorised speedometer service agent.
SPEEDOMETER CABLE
The speedometer cable is attached ro the speedometer
head by a 'push on' quick connect attachment.
The cable is lubricated at the time of assembly and should
not require further lubrication under normal conditions, for
40,000 km.
INSPECTION OF CABLES
1. Disconnect the speedometer cable casing at the
Figure 12-15 speedometer head by depressing spring retaining clip
Gauge Removal and pull the cable out of the upper end of the casing .
""""
1\)
I
""""
co
-)\ ~ m
~--,~,~ r-
/// ------- . . -=--1__ l
~~ ' \
/ ~- - -- -·· --:~-:e_-
' ... <>/ --.
m
£l::0
~- c\~)J
'i!~CP~e__v. .=--&cAs
SPEED~~~ETERCA /~
BLE
0)>
~'-
/- -- / -- · ~---
r - - _ __
- - - - - .p
'. (r/:0}) I J:Q

/1
d)
r-
~-------r-
/ ,' ~ \~. I,\-..----/ (r)Jj
~-
/ ---\ ~
'{QJ~
CJlk .:3 RETAINER~
6;:·
\ ~? ,.-'
'
----- ~ - r . d)
:'': .rrf\1 LOCATEBROADCASTCODE
\ -
I ' .
\
IN LINE WITH THE OUTER
'EDGE OF THE GROMMET. ~~5, M40, M21 ~
.------
(~ -
~
CABLE LAY MUST BE AS
SMOOTH AS POSSIBLE
MIN. PERMISSIBLE BEND
RADIUS 127 m m f ~ ~-~
~9 :/ /~@_
~l - r=~t~~,:&z."
--
/
~ ,11 "''\ ~j '
t~~]~--
//
~-~ d) DIP AT ASSMEBLY WITH HN-1046 TRANS. OIL. ALL MC6
Figure 12-17
Speedometer Cable Installation- Exc. M41
d) SEAL·
LOCATE BROADCAST CODE SECTION A-A

IN LINE WITH THE OUTER
EDGE OF THE GROMMET
-0 DRIVE ASSEMBLY
VIEW~
/
/
I
/ 8-11 Nm
·'
9,5-15 Nm
Figure 12-18
Speedometer Cable Installation- M41
12-20 ELECTRICAL
2. Inspect the cable for breaks or worn spots and kinks

VOLTMETER
which indicate lack of lubrication or sharp bends in the
casing. To check cable for kinks, hold one end vertical The voltmeter relates to battery voltage and may be
in each hand and slowly turn the cable; if the cable is checked with an additional, accurate voltmeter, should
kinked the loop will 'flop' . Replace the cable if kinked inaccurate readings be suspected . Make sure the battery
or distorted. terminals are clean and properly connected before carrying
3. Inspect the squared ends to ensure that they are in line out check.
with the cable and do not run out of true when rotated . Volts Pointer Angle
If necessary, lubricate the cable with lithium grease to GMH 8.0 .............................................................. .. 0 deg . ( ± 3 deg .)
Specification HN1225 to the lower two thirds of the cable 12.0 ( ± .4) ........................... ............... 44 deg . ( ± 3 deg .)
only. Do not use excessive grease. 16.0 ( ± .5) ......................................... . 90 deg . ( ± 3 deg .)
Insert the cable into the casing from the upper end and
connect the casing to the speedometer head. Make sure
that the cable tip seats correctly in the speedometer TACHOMETER
socket.
See Figs. 12-17 and 18 for installation of speedometer Calibration of a suspect tachometer should be checked
cable assemblies. against a known accurate tachometer and should not vary
more than or ±.3 percent of dial reading over a working
range of 400 to 5,500 rpm .
GENERATOR WARNING LAMP When installing a new tachometer ensure it is calibrated for
correct engine configuration fitted to vehicle.
The general lamp glows when the ignition-starting switch
is turned to the 'ON' position with the engine stationary, or
when the generator fails to charge with the engine running FUEL, OIL AND TEMPERATURE GAUGE
(refer to the vehicle wiring diagrams for the circuit con-
nections). The fuel and temperature gauge are thermal type gauges
and operate as follows:-
With the ignition on current flows through a solid state
OIL PRESSURE WARNING LAMP voltage stabilizer (which regulates output to 10 volts) to
The engine lubrication system incorporates a warning lamp windings on a bi-metal arm in the gauge. The current
which is controlled by a switch screwed into the main oil flowing through the bi-metal arm heats the arm which
distribution gallery. This glows whenever the engine oil deflects the pointer of the gauge. The amount of current to
pressure falls below 21 to 35 kPa. Should the lamp glow heat the arm and change the gauge reading is controlled
with the engine running, switch off and check the oil level. by the variable resistance of the sender units.
If it is full, disconnect the lamp wire from the switch and turn The oil pressure gauge is magnetic type, the pointer is
the ignition switch 'ON' . If the lamp still glows, there is a moved by changing the magnetic pull of the three coils in
short circuit between the lamp and switch. If the lamp the gauge. The magnetic pull is controlled by the variable
circuit is not defective, the switch and engine oil pressure resistance of the oil pressure sender unit.
should be checked by installing an accurate dial pressure The gauge wiring is from one coil through to the others to
gauge in place of the switch. earth, while the series connection between the coils is
connected to the sender unit terminal of the gauge.
BRAKE WARNING LAMP With the ignition on and engine stationary, sender unit
resistance is low and current flows through the first coil to
The brake warning lamp lights when a failure occurs in
earth via the sender unit and two coils in pareiiP-1 with the
either front or rear hydraulic system. If the light does not
sender unit. The pointer armature is moved magnetically to
come on as the ,ignition switch is turned to the start
the zero pressure position.
position, check for blown globe or open circuit.
As the engine is started, oil pressure increases the re-
If lamp is on and no apparent problem with brake system
sistance in the sender unit. This increased resistance,
is noted, disconnect wiring from switch on master cylinder,
forces the increased current to flow to earth through the
if light does not go out check for short circuit in wiring . If
two coils, increasing the magnetic strength and rotating the
light goes out, check switch for short or damage.
pointer armature to indicate the oil pressure.
Should switch and circuit prove alright, check hydraulic
brake system thoroughly. To check the gauges, disconnect lead to sender unit and
install variable resistance between lead and good earth . Set
resistance to values listed and check gauge readings .
PARK BRAKE WARNING LAMP
CAUTION: Do not operate any thermal type gauge unit
If. lamp lights with ignition on and park brake fully released, without a suitable earth connection to the voltage stabilizer.
disconnect yellow lead from under centre of dash see Even a short period of operation without an earth will result
wiring harness installation in this section . If lamp goe~ out, in damage to the regulator and gauge windings.
there IS a short circuit from lead to switch or switch is
damaged or shorted to earth. If lamp fails to light with park Fuel Gauge
brake applied (ignition on) and bulb is alright, disconnect Empty (± 3 deg.) Half(± 3 deg.) Full (± 6 deg.)
yellow lead at dash and short to earth . If lamp lights, lead 282 ohms 97 ohms 40 ohms
to switch is open circuited or switch is seized or damaged.
If lamp fails to light, lead or printed circuit is open circuited . Temperature Gauge
(For park brake switch replacement, see Brakes - Section Cold (± 3 deg.) Half(± 3 deg.) Hot(± 3 deg.)
5 of this manual) . 282 ohms 74 ohms 40 ohms
- ---------------------------------------------- ---------------------------- -
..
ELECTRICAL 12-21
Approximate Temperature outlined under Oil Pressure Gauge. If gauge is alright,

52° c 96° c replace sender unit. Sender unit may be checked in -
dividually with an accurate oil pressure gauge ana onm
Pressure Gauge meter using the following values:-
Low(± 3 deg.) Half(± 3 deg.) High (Ref.)
Pressure kPa
47 ohms 98 ohms 180 ohms
o±15 100±15 200±15 300 ± 15 400 500
Approximate Pressure (Ref Ref
100 kPa 250 kPa 500 kPa Only) Only)
Figures in brackets are gauge pointer variations. Resistance Ohms
10 47 80 114 148 180
FUEL GAUGE SENDER UNIT
Check that fuel gauge sender unit arm travel is to FUEL CONSUMPTION INDICATOR
specification as shown in Fig . 12-19.
The fuel consumption indicator may be checked against a
Using an ohm meter check that with sender unit in empty known accurate vacuum gauge, using a vacuum pump, to
position resistance is 282 or±.48 ohms, half full position 97 the following values:-
or ±. 14 ohms and full position 40 or ±.50 ohms. (See
Section 8 Fuel & Exhaust Systems for removal operations) . Vacuum mm Hg
0 114 229 750
Pointer Angle
TEMPERATURE SENDER UNIT 00 35°± lf> 770± 11 2700± 17
To test temperature sender unit use a ohm meter and If gauge is alright check hose for leaks, kinks or blockages.
immerse lower portion of switch in a mixture of water and See Figs. 12-20 and 21 for hose installation.
glycerine of 1.046 specific gravity at 20 degrees C (ap-
prox. 30 volume percent glycerine) or light engine oil. IF
USING ENGINE OIL DO NOT HEAT ABOVE
1 00 degrees C.
Raise temperature gradually and note ohm meter readings
which should be as follows:-
Temperature "C"
52° 60° goo looo
Resistance Ohms
282 217±36 40
(Ref Only) (Ref Only)
OIL PRESSURE SENDER UNIT

If oil pressure readings are suspect, disconnect lead at
sender unit and check gauge using variable resistance as
E
E
co
("')
EMPTY
STOP
Figure 12-19
Fuel Gauge Sender Unit
......
1\)
I
1\)
1\)
m
8 VL r-
RESTRICTOR m
~
::0
0
l>
r-
8VK ~<:::.::::_
/-
//
:-:. '~
'--··~
-~ ~ I
fo /./
CLIP (8VK)
~
6 CYLINDER ENGINE
I FOR SECTION A - A, VIEW B, REFER FIGURE 12-21
Figure 12-20
Fuel Consumption Indicator Hose Installation (Engine Compartment)
FUEL CONSUMPTION
INDICATOR
/?:~?
~P?a~~ \0
~ ~..lr' SPEEDO
'~ ~-'{/)
// y -- CABLE
,·
/~.f··
I \""' ---'· _,./ .. / .
/'
d(;. HAND CHOKE CABLE
VIEW[m
8VL & C60 8VL EXC. C60
SECTION A-A
STEERING SUPPORT /
BRACKET~
'~
,/
A~;;;s~ - -
MAIN WIRING HARNESS___.--
'"'! '
· .~........_____·. ;-.....
---
SECTION B-B
VIEw IAI I
~.........._
m
r-
m
£1:IJ
0
>
r-
~
1\)
Figure 12-21 I
1\)
Fuel Consumption Indicator Hose Installation (Installation Panel) w
12-24 ELECTRICAL
PUSH CLOCK INTO CENTRE AIR

OUTLET NOZZLE ASM. UNTIL
LATCH ENGAGES.
FOR WIRING CONNECTIONS

REFER FIG. 49 & 49(a).
Figure 12-22
Clock Installation
CLOCK horn contact and turn signal switch are serviced as an

assembly. To replace refer to 'Windshield Washer / Wiper
The clock has a knob on the front face for time setting, and Control Stalk' removal, Fig. 12-24.
should be taken to an authorized service agent if any
appreciable loss or gain in time is observed . For installation
of clock see Fig. 12-22. WINDSHIELD WIPER & WASHER
ASSEMBLY
HORN
8VK models are equipped with a low note horn 8VL and
GENERAL DESCRIPTION
8VX models are equipped with an additional high note Two speed wipers are standard on 8VK models, 8VL and
horn. A horn relay is fitted on all models. The relay permits 8VX models are fitted with two speed wipers and a dwell
control of the horns with a small amount of current passing control unit. All models are fitted with electric demand type
through the horn button contacts. The relay is located in the windshield washers. Wiper arms and blades have a matt
fuse panel. black finish to prevent glare.
VOLTAGE TEST AT HORN WIPER ARM

An improperly operating horn or circuit can be tested by
connecting a voltmeter between the horn terminal and Replacement
ground and noting the voltage when the horn button is 1. Hinge end of wiper arm covering spindle nut.
pressed . 2. Remove nut and pry arm off spindle.
No voltage indicates trouble in the horn button, circuit, 3. Fit arms with blade set to dimensions as shown in
relay or ground. Fig . 12-23.
Less than 9 volts indicates resistance in circuit or short
circuit in the horn. WIPER MOTOR & LINKAGE
Voltage between 9 and 11 indicates the circuit is al-
right: look for sticking or improper horn adjustment.
Removal
Above 11 volts indicates improper adjustment or open 1. Remove wiper arms as previously outlined.
circuit in horn . 2. Remove hex nut from wiper seat and remove washer
and damping rubbers.
HORN ADJUSTMENT 3. Remove engine compartment to engine hood sealing
1. Remove the horn. strip and remove plastic wiper assembly cover.
2. Connect an ammeter in series with the horn and a fully 4. Remove wiring connector from wiper motor and dis-
charged battery. connect earth lead.
3. The current draw should be 6.5 amps (max.) for either 5. Lower wiper assembly and slide motor mount plate
high or low note horn at 12 volts. from fixing rubber Fig. 12-23.
4. Replace horn. 6. Remove wiper crank from motor and remove three
If the horn does not operate satisfactorily, it should be screws retaining wiper motor to mounting plate.
taken to an authorized agent for repair.
Installation
HORN ACTUATOR 1. Install in reverse order, setting wiper blades to
A horn bar is fitted to all models and is non-adjustable. The dimensions shown in Fig . 1 2-23 .
ELECTRICAL 12-25
50.:!:_ 5
~ mm
EARTH LEAD
FIXING RUBBER
DAMPING RUBBERS
. Figure 12-23
Wmdscreen w·•per Installation
I 1 ......
1\)
I
1\)
& -- en
m
' l ----7
ill- r-
m
_,//
£l
~~~~~>-
TURN SIGNAL &
HAZARD WARNING
- WIPER/WASHER
:::D
~
SWITCH -.......__
AND HEADLAMP
DIMMER CONTROL ASSEMBLE SUPPORT ASM . WITH
CAMS IN THIS POSITION r-
.~ KNOB
VIEW IN DIRECTION OF ARROW
./'
ASSEMBLE THRU STEERING
COLUMN HOUSING & SELF TAP
INTO PLASTIC SUPPORT OF
SWITCH HORN
/ BAR
~
""'
-A-A FOR CONNECTION TO MAIN
I
SECTION
WIRING HARNESS REF . FIG. 12-49
L coAT ELECTRICAL
CONTACT SURFACE
-r:::::-=--
________ _,..
l2'2 19-22 Nm
WITH HN 1346 SECTION B-8
ffi 2-2.5 Nm
Figure 12-24
Wiper/ Washer & Headlamp Dimmer Control Stalk and Turn Signal / Hazard Warning Switch Installation
----- .. ---------- ~ ..________ .
. .......____~
( v \lla llll ~ ' --- ........
~---~-~~
~~------... (
t~~
\- ~
\-- ~- \\
I
~ CONTROL UNIT
ESCUTCHEON
A,SM \
NUT ~
\
\
\
~ BODY,POTENTIOMETER &
HARNESS ASM .
> m
r
~ m
~ - KNOB
VIEWIAJ <SCREW
Q
::D
0)>
VIEWIBI r
.....
1\)
I
Figure 12-25 1\)
Dwell Control Assembly Installation
"""'
.....
1\)
I
1\)
r *JETS MUST STRIKE WINDSHIELD WITHIN

co
-~~2 ~~ m
I THIS 150.0 DIA . TARGET AREA
(b. .· r-
PLACES
m
/~
WI //
~
::0
~ ~-
- WINSHIELD WASHER
PU MP ASM . 0
- /// I )>
WIRI%~RH~OSE~ /~)
ROU T E WINDSHI I / // / ·"~
<t.. OF CAR.
r-
WAS INELD • • >
RES'R~OLEAOS
VIEW!m ,_·/// 350.0 1
2PLACES RNESS CLIPS ·"/ I / / , '-._>-./ --~--

~EN SURE HOSE
-·~
~-
' '- 500.0 ,
VIEW [A] UNDER PASS '-. /
'' ' ' '.,
"''
c:Y
/
/ . / ' (!'/7\ /
/
"'-;.( '
160.0
/ -.J
LOCATION . IR AT THIS "" '
-~"''~
Cc ,_·
'cO>
L
.=---"'"'-• ._, // '
-lcl~ "
1>-
I '--->- . ' ;'--" I
~
j}J"<:' ~ ~--~~/
A<ii;;iif '''": 6 7'
~~ !1/t- :-·~,r?~·'l ~-~~c ·:_, ..

( .
"~
,'1 ·. I
R ESERVOIR "'" ;,i •.. .
·• c:..,:.
~-- - -_I
I I
,_, n '
; ~~
1- · 5oo.o I
"'-.-~:·~ !\.~
· · -->- I . !
' 8 /
;>
,,
. •
J._\ ""'"<--
I
~~I :>. ~
_· ~ I~ ~-
1 ' '.. !
' .;;,
"711 .' I \"
"" '
. - ' ' V
.. ~
'
;~~$" -~ '
' i
\
. >, /
'.
.
/ ,;
,, .
I-
> -
'
lQ] ' .
9 '---.
..,____
~ .- I PUMP - - ', - ID ' >-
'-~- \ ARROW
OF TO PO INT IN DIRECTION
TEE PIECE
"
I
NOZZLE ~
/ -- )"·
I
r:=.·.
CANISTER VIEW (E)
BRACKET
NON RETURN DIM. IN mm
INSTALLATION
VALVE
' - TEE PIECE
VIEwiCI & 9.0 -12 .0 Nm
Figure 12-26
Windshield Washer Assembly
ELECTRICAL 1~-29
WINDSHIELD WIPER / WASHER CONTROL STALK fitted to the lower front end panel are activated . Once the
cycle is completed, the wash/wipe button must be pressed
Removal again to activate the system. The windshield wiper must be
1. Disconnect battery ground cable. turned off manually.
2. Remove horn bar (Fig. 12-24).
3. Remove steering wheel using tool No. 9A-1 and two HEADLAMP WIPER ARM
M8 x 1.25 x 76 mm. bolts.
4. Disconnect and unclip wiring harnesses. Replacement
5. Unscrew hazard warn ing knob from turn signal switch. 1. Lift cover on wiper arm and remove attaching nut.
6. Remove screws retaining control stalk and switch 2. Pry arm off spindle by laying a screwdriver handle
assembly and remove units, feed harness through along motor mounting bracket and prying arm off with
shroud. a 1 0 mm open end spanner. Fig . 12-27.
3. Replace in reverse order so that at its extreme length
Installation of travel, the arm is aligned with the triangular mark on
1. Replace in reverse order torq ueing steering wheel nut the headlamp lens, Fig. 12-28.
to 19 - 22 Nm and lock nut fingertight plus 1 I 4 - 1 /3
turn.
DWELL CONTROL SWITCH
Removal
1. Disconnect wiring harness connectors (Fig. 12-25).
2. Pry switch from dash and feed wiring out thro ugh
appature.
3. Pull knob from switch, unsc rew keyed retaining nut and
remove escutcheon.
Installation
1 . Reverse removal operations.
WINDSHIELD WASHER PUMP
Replacement
1. Disconnect electrical and hose connections Figure 12-27
(Fig. 12-26). Removing Headlamp Wiper Arm
2. Pry out washer pump which is a snap fit into the
reservoir.
3. Replace in reverse order.
WASHER RESERVOIR
Replacement
1. Remove washer pump as previously outlined
(Fig. 12-26). HEADLAMP WIPER MOTOR
2. Remove evaporation canister retaining bracket and
reservoir retaining screws. Removal
3. Replace in reverse order. 1. Disconnect wiring harness.
2. Remove wiper arm as previously outlined.
WASHER NOZZLE
3. Remove seal and retaining nut from spindle and re -
The windshield washer nozzles are a snap fit into the cowl move wiper motor, mounting brackets and seal from
panel, refer Fig. 12-26. body. (Fig. 12-28) .
Installation
1. Reverse removal operations aligning wiper arm as
HEADLAMP WIPER/ WASHERS previously outlined.
NOTE: Wiper motors are marked 'L ' and 'R ' for left and
GENERAL DESCRIPTION right side installation.
The headlamp wiper/washers, fitted to 8VX models, op-
erate for 6 seconds when the headlamps are on and the TIMER
stalk control wiper/wash button is depressed. When the The timer for the wiper / washer system is located behind
system is activated a solenoid valve opens, allowing water the right hand spring tower. Should it be suspect, dis-
from the windshield washer pump to be directed to the connect harness and plug into a known good unit.
nozzles in the bumper bar. At the same time, wiper motors (Fig. 12-29).
12-30 ELECTRICAL
WIPER ARM
FOR SEALING BETWEEN MOTOR FACE

PLATE AND PANEL, USE NEOPRENE
CONTACT ADHESIVE.
NUT
----
PARK POSITION
R . HAND SIDE SHOWN, L. HAND SIDE OPPOSITE
Figure 12-28
Headlamp Wiper Motor Installation
WASHER SOLENOID VALVE WASHER NOZZLE

To check solenoid valve operation : The headlamp washer nozzles are snap fitted to the front
1. Disconnect electrical connector from solenoid bumper, take care to depress tangs under bumper if re -
(Fig . 12-30) . moval is necessary. See Fig . 12-30 for installation and
2. Disconnect hoses to nozzles and tee piece from aiming .
solenoid .
3. Connect hose to solenoid to tee piece connection and
blow through hose, no air should exit from either left
or right connections.
4. Activate solenoid using jumper leads, blow through CIGAR LIGHTER
hose to tee piece connection , air should now exit from Three different makes of lighter may be used in production.
left and right hose connections . It is recommended that, should replacement be necessary,
Replace unit if faulty. a complete unit be used .
__ , =.:_-_-__ o'
-::- cs-:=:-
~;;:~ \ \
-----~- - "'~?- ,;:T, ;:-.::;
- . -~ ~ . ~~~~_0 ~
CL/
IPS-~
\ ·~ - ·:~' -- ~~~~~ -
:? ·~~ rf\0
7_,.--:::
I ~ --
' '"'" /, , ,
' FOR INSTALLATION OF HEADLAMP
WIPER MOTOR REFER FIG . 12-28.
,_
"- MAIN WIRING HARNESS ,

[g
, _______ ;~ , -,/'
TIMER -- RELAY '
~
lL;~~ ;.~~~
j
~ • ' A ~
r· .-: .- . ;;u
/
- ~~ L ,
/-
//
. Ar A / '
' '/ ./
WIPER HARNESS -,- m
r-
, IO:x"
/
m
VIew IAI
\-,; ~
=~ l ~j_ £1
:0
VIEW[g
SECTION A-A 0
:t>
r-
......
I\)
I
Figure 12-29 (1.)
Timer, Relay & Headlamp Wiper Harness Installation ......
......
1\)
I
w
1\)
t" "l ' ' m

r-
- ..• - .....\ ~
m
f _'__
'/ lii1
~~ TO WINDSHIELD WASHER ~
\ ·L-- r\~· fA1 - _fo:-',...- ~ JETS :a
•?;;:'~ ~. ~~ .c-<
~,,' &. ~
"""'~ ~ ~
0)>
~ =-· -1' ;·~-~~ ~ // \ ' v
\ . \ . \::?'.
~ r-
____) . £
vr
,, ~ ~
};' )-~<·, - . "'\.__>
~-- B '
'~; ~~
·>,)}
'ilf" '
~~ ~ ~0,
. /~~
/
«
\ )
'EL.--T~ -
~\B
~
,.....--_ .'--- - -
--~-
.,,
w 1/J- CJ
- T-
I
I
-"'T EE PIECE
~ ~ "'~i
Q
d'
~ /~ /
/.
-
_'::/
.-:'
\
- .. -,\Jj
/ '-'j '\\-: :1
I '
,-- "'-.:-: :.
- A
-~ li5l L TO SOLENOID- HEAD LAMP
\ -.tr'
--:AI vr;;: x VIEW~ WINDSCREEN WIPER &
\ ~- ,o _..--
8'
- - WASHER
0~
- { --_"'- -'~FC~
~---
\_ / - ---- . --
-. \ l [ 'o"""'___ - ._.4!
-"'---~ - \--- ~ .. /
~
~J-L
t&·
.: HEAD LAMPS WIPER HARN.
REFER FIG. 12-29
NOZZLE TO BE AIMED \
TOWARDS CENTRE OF "
HEADLAMP · NOZZLE
4
~~:J/
=-'s '1 r:rs-"'UJ ~
~l...-- ' •
~
~_(fiis'V,/
-~;\":s:s. ''\. TO 'T' PIECE ( \__
,........ 7! - ·- :\ I ---,.
~.....
Clff
,--~~
~
APPLY 'BODYGUARD' HN1427
AROUND THE EDGE OF HOLE
·- BUMPER BAR ll
~
r BUMPER MOUNTING
1BRACKET
TO RH JET
[t-- TO LH JET ~ MAIN WIRING
- HARNESS
;_. l /
~~/ C-i\_
--"". 0 '
g_.o :i-
SECTION 8-8
~CLIP VIEw IAI j
2 PLACES SECTION D-D

-
""
R.H. SHOWN, L.H. OPPOSITE SECTION A-A
3 PLACES
Figure 12-30
Headlamp Washer Assembly Installation
ELECTRICAL 12-33
SPECIFICATIONS
GENERATOR CHARGE INDICATOR ............... Glows when WINDSHIELD WASHER
generator is not charging Make ......................................................... Lucas, AC Delco
OIL PRESSURE INDICATOR .............................. Glows when Type ........................................................................... Demand
oil pressure falls to 21-35 kPa Delivery Pressure ................................... 83kPa minimum
OIL PRESSURE GAUGE .... ........... Scale range: 0-500 kPa (with jets blocked)
TEMPERATURE GAUGE ......... Scale range Low: 0 deg . C Water Volume .................. 12 c.c. per second minimum
Half Scale: 96 deg . C (through two .8 mm Dia. jets)
Full Scale: 120 deg . C Current Draw ........................ 3 amps. max at 13.5 volts
VOLTMETER .. ...... .... .. ............. .. Scale range Low: 8 volts HEADLAMP WIPER MOTOR
Half Scale: 1 2 volts Make ............................................................................. Bosch
Full Scale: 16 volts Voltage ................................................................................. 12
HORN Speed (No Load) ................... 52± 8 rpm at 13 volts
Make .............................................................................. R.V.B .
Current Draw .................................. 6.5 amps at 12 volts
CIGAR LIGHTER
Make ...... ............ .. .... Preslite, Cleardrive, Carr Fastener
Current ................................... 9.5 amps max. at 14 volts
Time for Plunger to Eject ................ 11 ± 4 seconds
at 9.5 amps max.
WINDSHIELD WIPER MOTOR
Make ...................................................... Lucas and Preslite
Voltage .............. .. ... ... ........................................................... 12
Speeds .................................................................................. . 2
Low
with 4.5 Nm drag ............ 35 rpm plus or minus 3,
Draw 8 amps max. load
No load current ............................................ 2.5 amps
High
with 4.5 Nm drag ............ 50 rpm plus or minus 5,
Draw 8 amps max.
No load current ............... ............................. 5.0 amps
.....
1\)
I
(,)
SPEEDOMETER GEAR CHART ~
m
r-
m
DIFF. TRANSMISSION
DRIVE
TYRE OPTION
~
OPT. RATIO OPT. DRIVEN GEAR ::D
GEAR
0
)>
17 TEETH 37
r-
G70 2.60:1 M41 RED OBC ocv OCH XCH ZCH
STEEL BLUE TEETH
M40 19
8 TEETH * PINK *
GU7 2.78 : 1 & 18 OBC OCJ OCR XCR ZCR
WHITE BROWN
L6 TEETH
M40
&
9 TEETH * GREEN
21
20
.
OBC OCJ OCH XCH ZCH
BLUE WHITE
v8 TEETH
7 TEETH
GU4 3.08:1 MC6 RED 18 OBC OCJ OCR XCR ZCR
M40
M20
BROWN
8 TEETH
WHITE
GREEN
WHITE
21
20
.
OBC OCJ OCR XCR ZCR
TEETH
L6
V8
17 TEETH 43
M41 PURPLE OBC OCJ OCH XCH ZCH
M20
M21
STEEL BLUE
8 TEETH
WHITE
* GREEN
WHITE
TEETH
21
:20
.
OBC OCJ OCH XCH ZCH
I
I
TEETH
9 TEETH 23
M40 RED OBC OCJ OCH XCH ZCH
BLUE TEETH
M20 8 TEETH 22
GV4 3.36:1 OK. BLUE OBC OCJ OCR XCR ZCR
M40 WHITE TEETH
8 TEETH 22
M21 DK. BLUE OBC OCJ OCH XCH ZCH
MC6
WHITE
7 TEETH
BROWN
BLUE
TEETH
20
19
.
OBC OCJ OCR XCR ZCR
YELLOW TEETH
GV7 3.55 : 1 M20 8 TEETH

WHITE
RED
• YELLOW
23
24
.
OBC
OCJ OCR XCR ZCR
TEETH
• = USED WITH THAT TYRE OPTION ONLY

ELECTRICAL 12-35
RADIO- TAPE PLAYER

INDEX
GENERAL .......................................................................... 12-35 RECEIVER ......................................................................... 12-42
STATIC & NOISE .............................................................. 12-42 REMOVAL .................................................................. 12-42
POPPING NOISE .............................................................. 12-42 INSTALLATION .......................................................... 12-42
ON CAR DIAGNOSIS ...................................................... 12-42
GENERAL
All 8VK & 8VL models are equipped with AM radios as radio system problems before removing the radio for re-
standard equipment, an AM / FM high performance radio is pair.
optional on these models. 1. Turn ignition to the accessory position and turn radio
8VX models are standard with AM / FM stereo radio / tape on .
players and may be fitted as an option to other models. 2. On AM / FM radios if the radio is dead on FM but the
Because radio problems are most often repaired at auth- AM plays normally, the radio should be removed for
orized warranty repair agents, the tendency is to remove repair. (The reverse of this condition does not nec-
the set when a problem is reported , without any preliminary essarily call for radio removal.)
diagnosis. 3. On combination radio / tape units, if the radio operates
Many times when this is the case, the trouble could have properly but the tape player does not, the unit should
been corrected without removal of the radio . be removed for repair. (The reverse of this condition
does not necessarily call for radio/ tape removal.)
The following quick checks are used to elminate external
4. For more detailed diagnosis, see Figs. 12-32 & 33 .
....
1\)
I
WITH ANTENNA FULLY EXTENDED, TUNE RECEIVER (A)
TO A WEAK SIGNAL NEAR 1400kHz AND ADJUST (7)
TRIMMER FOR MAXIMUM VOLUME' WITH SPECIAL
TOOL SUPPLIED . m
r-
m
~
::D
0)>
r-
TRIMMER TOOL
AM/FM RADIO
TRIMMER TOOL
AM RADIO
TRIMMER SCREW
RADIO/CASSETTE TAPE
PLAYER
Figure 12-31
Trimmer Adjustment
ELECTRICAL 12-37
See Fig. 12-38
WHINE OR WHIRRING SIREN SNAPPING, CRACKLING

LIKE SOUND VARIES IN POPPING SOUND WHEN
PITCH WITH ENGINE SPEED AN ELECTRICAL DEVICE
CHANGE AND DISAPPEARS IS DIAECTL Y OR
WHEN ALTERNATOR IS INOIRECTL Y ACTIVATED
UNPLUGGED
CUSTOMER'S
RADIO BOTH RADIOS
CONSIDERABLY RELATIVELY
WEAKER WEAK
RECEPTIO~ RECEPTION
Figure 12-32
Radio Diagnosis
12-38 ELECTRICAL
r TURN ON IGNITION
1
I TURN ON RADIO AND/OR
TAPE PLAYER
r VERIFY CUSTOMER COMPLAINT/

IDENTIFY SYMPTOM
$
I
CHECK RADIO THEN TAPE PLAYER
CHECK TO SEE IF ALL SPEAKERS
f ARE DEAD fUSE FADER TO CHECK)
NO YES YES
see Fig. 12-37

r r -1
I TEST SPEAKER($)
l TAPE ONLY DEAD
!USING AN OHMMETER. MEASURE FROM

ALL TERMINALS TO GROUND
I
r
I
CHECK PLAYER OR
OBSTRUCTION
THROUGH TAPE DOOR
l
I INTERMITTENT
I ALL OPEN I ONE OR MORE SHORTED
l
I
NO OBSTRUCTION OBSTRUCTION
r
MEASURE ACROSS EACH
SPEAKER
REPAIR OR REPLACEl
HARNESS, RECHECK r I
REMOVE OBSTRUCTION
I
RADIO
40HMS I OPEN
SUBSTITUTE KNOWN
GOOD TAPE CASSETTE CAUTION IMPROPER
I II I
NOTOKl OK REMOVAL MAY DAMAGE
l
TAPE PLAYER
DETERMINE IF RADIO
REPLACE SPEAKER
OR REPAIR REMOVE
DEAD I WORKS
IS INTEAMITIENTLY
REMOVE
RADIO CONNECTION RADIO
STOP
I I
I I r
WEAK, DEAD OR
NOISY, THEN REFER
TO THE APPROPRIATE
RADIO CHART
REMOVE PLA YEA FAULT WAS WITH
TAPE CASSETTE
1
I AM AND FM OEAD
OR AM ONLY DEAD
I I FMONLY DEAD
r All MODES DEAD l
CHECK THAT ANTENNA IS
PLUGGED INTO RADIO . MAKE
I r
I
REMOVE UNIT
I CHECK FUSE I
f SURE PLUG ISN'T LOCKED
FUSE OK FUSE BLOWN
GOOO CONNECTION f BAD CONNECTION

I
l CHECK AT THE RADIO
FOR FAUL TV POWER UNPLUG RADIO
CHECK ANTENNA ANO

LEAD-IN AND SUBSTI -
TUTE ANTENNA TRIM f--
r REPAIR CONNECTION
I CONNECTION OR
SPEAKER CONNECTIONS
POWER LEAD
REPLACE FUSE
BAD
I
I GOOD
NO RECEPTION RADIO WORKS

I REPAIR
r REMOVE RADIO
I REMOVE RADIO
I REPLACE MAL-
FUNCTIONING
ANTENNA OR
FUSE BLOWS AGAIN
r
FUSE DOESN' T
BLOW
LEAD-IN
RE -TRIM CHECK ALL ACCESSORIES
ON FUSE FOR PROBLEM
(SEE SERVICE MANUAL
TEST DRIVE IF NECESSARY.)
1
I CORRECT PROBLEM
I l
I PLUG RADIO POWER
LEAD SACK IN
RADIO WORKS I FUSE BLOWS
I I
I STOP 1 REMOVE UNIT
I
Figure 12-33
Radio Diagnosis
/1A1rm\
-~-~:Y/1
~ 7J1Jt:t~§~o~~~
/ ,:__Q /
ft. SCREW -"'

-2PLACES ~
SPEAKER MOUNTING
PLATE
FOR CONNECTION TO MAIN WIRING
HARNESS, REFER FIG . 12-50
NUT- - · ··
MASK DEADENER AROUND 1 i/~J,--~

ANTENNA MOUNTING HOLE 1 /r·."..<~~v/?c 7f::
·1 .
-- .
~-------
/
AND COAT WITH HN1062 - / lA ' . ·J,y
~
/. ' /
-- .,._,____
I . I ·'-' I.-
.Y '
~~ RETAINERASM. .<1'
f'iii &scREW
VIEWL!:!J
VIEW [C)
m
r-
& 2,0-2,8Nm
m
&. Q
2.4-3.4 Nm :::c
0
~
r-
Figure 12-34
"""
N
I
w
AM Radio Installation CD
.....
1\)
I
1DJ INSTALL ANTENNA LEAD IN CABLE ~
/ /1 c
r WHEN NUT IS TIG HTENED L£1 \ IN CLIPS AS SHOWN
m
KEY OPENING MUST
FACE OUTBOAR D
[6] / r-
--- - ...::::-- ---- ' 6 7
~~- J
I
/
m
Q
:I]
~~
0)>
/
r-
'~
j FOR CONNECTION TO MAIN WIRING
HARNESS, REFER FIG . 12-50.
I
':
\ ·.
J
\
\
--
<----::::::>">---
---......._ ..
~>------- ~~,_
RETAINER ASM. ~~--~~-
& scREW , · , -~ -
\ u - -::.....
'
VIEW!g
............___
.7 -~
{::_-.,.,"' - ' -'-tl
--<. ~ rS:.
\.,:,·~
h.__ i
I~ ~ '' ~
~. :t
-
'0'" I
v :J I ~
"'-- RETAINING SPRING
ESCUTCHEON
\_ - TONE CONTROL KNOB fAl
'- ON/OFF/VOLUME KNOB VIEW~ f\..
i l l 2,0-2,8 Nm
& 2.4-3.4 Nm
Figure 12-35
AM / FM Radio Installation
~~
/ ,-_ - ---- INSTALL ANTENNA LEAD -IN CABLE
~
WHEN NUT IS TIGHTENED / - -- . [ill IN CLIPS AS SHOWN
KEY OPENING MUST / -------- fl\1 \ .7
lAJ ,',
. - ~-,
FACE OUTBOARD _
1 .r-"7- -
. ' --.:...:::_.:::::=:-:-- .. .. . - - - . ~- / /I
U I • -~::-<. / /"· - ', --_. . I'
~- -
·~ .
ffi SCREW - - 'td: ,, '
- 2 PLACEs·- ',;
SPEAKER MOUNTING / .
~
V ~--~-------
\ PLATE _ _ _ _ _/
, , I / ,I 11
NUT-~- -~ ~
~
I
J
N ... t , u
,-I , : ; ~ - FOR CONNECTION TO MAIN WIRING
rFl
~
: \./ , _ / HARNESS, REFER FIG. 12·50
J_.- MASK DEADENER AROUND I / -

«:i I
· ..
~0
. ', ANTENNA MOUNTING HOLE . ' . · '·--~ - -, ..A
.. ' AND COAT WITH HN 1062 / <.--·· - --- / • r..· _! ---.. ' j
- ::---... 1
// f/
/
- ~-
--- u._/'~
- --~
'/
\. ....,\ ..._
---
-_'-,--/ ~---=-- .-·n
VIEWIBI
'..
VIEWICI
-' m
r-
m
/.
£1
:D
L_2j, 2,0-2,8 Nm
/
c~\ 2,4-3,4 Nm ~
•......
1\)
Figure 12-36 I
~
Radio / Cassette Tape Player Installation ....L )
12-42 ELECTRICAL
STATIC & NOISE 2. A known good speaker is connected totheradiooutput.

(If equipped with rear speaker, fade the output be-
Ground strap connections must be clean and tight, spark tween both speakers.)
plug cables must be TVRS type and in good condition. 3. A known good antenna is supplying a signal to the
Extra electrical equipment added to the car could cause
input. (FM can give weak reception with a bad antenna
static if not properly grounded or wiring was improperly
- so check antenna on AM .)
routed . Radio and antenna lead -in grounding must be clean
and tight. An improperly trimmed antenna adjusting screw
could result in poor sensitivity and static / noise on AM RECEIVER
stations only.
REMOVAL
Weak FM station reception will be affected by near-by
buildings, car speed , direction and windshield wiper op- 1. Disconnect battery ground cable .
eration. These 'flutters ,' 'swish' and 'fading ' conditions are 2. Remove control knobs, nuts and escutcheon and re-
characteristics of weak FM signals. move nuts attaching retaining spring to receiver. On
the radio / cassette player, a special nut is used to
POPPING NOISE retain the escutcheon, use Robert Bosch Tool No. 8-
603-360-002 to remove .
Operating switches such as turn signal , pushing in ci garette
lighter, operating stop lights, etc. , may cause a popping 3. Using a pair of pointy nosed pliers in the holes of the
noise on distant AM (weak) signals. Adjusting the antenna retaining springs, remove springs and withdraw re -
trimmer, if it is out of adjustment, will minimize the noise. ceiver from retainer and disconnect antenna lead ,
Fig . 12-31 . Always determine the exact nature of the radio wiring connector and earth lead .
problem as an aid to diagnosis. Knowing whether the
cons:Jition is intermittent or constant, whether it occurs with
INSTALLATION
engine off or running , and whether it occurs with car sta- 1. Reverse removal operations.
tionary or moving will help to pinpoint the problem. For rear speaker and fader control installation see
Fig . 12-37.
ON-CAR DIAGNOSIS For coil and generator suppressor installation see
Check to see that: Fig. 12-38.
1. The battery is supplying 12-14 VDC to the radio's For power antenna and switch installation see Figs. 12-
power connector. 39 & 39a.
./
WASHER-SPRING
(2 PLACES)
VIEW[§]
Figure 12-37
Rear Speaker Installation
POSITIVE TERMINAL
SPRING WASHER
EXTERNALTOOTHLOCKWASHER
gj..___ /r~ SLOTTED SCREW
r r ~
INTERFERENCE SUPPRESSION
CAPACITATOR
~
PAN HEAD CROSS
RECESS SCREW INTERFERENCE
~
SUPPRESSION
CAPACITOR
J~
T i SUPPRESSOR MUST BE
HORIZONTAL BOSCH
L6 ENGINES
Q
"
m
r
m
LUCAS
~
JJ
V8 EN GINES 0
)>
r
.....
1\)
Figure 12-38 I
~
Radio Suppressor Installation w
~
1\)
I
~
~
r LOWER INSTRUMENT PANEL

.,mm
Q
:::c
0)>
r-
VIEw IAI
~ ~
~ ~r"l
CLIP
(3 PLACES) LOWER FACIA PANEL
SECTION A-A
FOR VIEWS [ill[Q[Q] REFERFIG.12-39A
Figure 12-39
Power Antenna Installation
FINGER TIGHT PLUS
ONE FULL TURN "'
FRONT FENDER / , ,;:-::::~ _·- j- PO~-PERATEDANTENNA

/ I I ~~ HARNESS REF. FIG 12-39
SNAP FIRMLY -~ ~......_____
i\~
:;t]Yi l ~~,~- ~
WHEELHOUSE
BRACE
~_;- '~~
INTO POSITION..___ •·
...._ -J
'-
~ l
I~
/
.....
,,
:::-.._"'1
I
ANTENNA "- - " "'-0 1
:
SWITCH ASM. ~ ..,. ____ ; ---~ -::.\~ !I !

SIDE PART
....
DASH PANEL POWER ANTENNA ASM.
MASK DEADENER AROUND
\ ~,..._
::-....-
"'-L~
ANTENNA MOUNTING HOLE \ I I ::-.... ~~
AND COAT WITH HN1062 \ '. ~ \ ~-
~~I
NUT
- DRAIN TUBE
\\\ ~-~,
VIEW[Q] VIEwlCl
'- HEX. HEAD SCREW
FLAT WASHER
[}f)~
i/ , ®)
VIEW[§] GREY
BLACK
m
....
~
WHITE -
YELLOW - - m
GREY - Q
::tJ
vaEwlEl 0
l>
....
~
1\)
I
Figure 12-39a
~
Power Antenna Installation U1
12-46 ELECTRICAL
NOTES
ELECTRICAL 12-4 7
WIRING HARNESS
INDEX
FUSIBLE LINK ................................................................... 12-47 REAR LAMPS & TANK UNIT HARNESS
REPLACEMENT (L6) ................................................ 12-47 INSTALLATION ................................................................. 12-55
FUSE PANEL ..................................................................... 12-47 MAIN INSTRUMENT PANEL HARNESS
REMOVAL .................................................................. 12-47 INSTALLATION ................................................................. 12-56
INSTALLATION .......................................................... 12-47 MAIN INSTRUMENT PANEL HARNESS
PRINTED CIRCUIT ........................................................... 12-48 (REAR VIEW) .................................................................... 12-57
REMOVAL .................................................................. 12-48 INSTRUMENT PANEL AND DOOR SWITCH
INSTALLATION .......................................................... 12-48 HARNESS INSTALLATION ............................................. 12-58
BATTERY LEAD INSTALLATION (L6) ......................... 12-49 ENGINE COMPARTMENT HARNESS INSTAL .......... 12-59
BATTERY LEAD INSTALLATION (V8) ........................ 12-50 REMOTE CONTROL COMPARTMENT LID LOCK
ENGINE HARNESS INSTALLATION (L6) .................... 12-51 HARNESS INSTALLATION ............................................. 12-60
ENGINE HARNESS INSTALLATION (V8) ................... 12-52
POWER OPERATED SIDE WINDOW &
BODY HARNESS INSTALLATION ................................ 12-53 DOOR LOCK HARNESS INSTALLATION ................... 12-61
REAR HARNESS INSTALLATION ................................ 12-54 HEATED REAR WINDOW HARNESS INSTAL .......... 12-64
FUSIBLE LINK FUSE PANEL

The fusible link, used to protect the chassis wiring should
a short circuit occur in an unfused circuit, is located at the REMOVAL
starter motor main terminal on 6 cylinder models and on 1 . Remove cover.
V8 models connects near the battery positive terminal end 2. Unclip retaining tangs attaching lower part of fuse
of the starter cable with push in connections. panel to dash and slide fuse panel towards centre of
car and down .
REPLACEMENT (L6)
1. Disconnect battery ground cable. INSTALLATION
2. Remove fusible link from starter motor main terminal, 1. Locate upper legs of fuse panel into groove in dash
expose and cut directly behind connector. and snap into place.
3. Bare wires and new fusible link approx. 13 mm, 2. Replace cover.
position splicing clip around wires and crimp securely.
4. Solder crimp connection and starter connection to
fusible link using core solder. Use only sufficient heat
to obtain good solder joint.
5. Tape exposed wires and reconnect starter motor ter-
minal.
6. Reconnect ground cable.
12-48 ELECTRICAL
PRINTED CIRCUIT (COMBINED

INSTRUMENT ASSEMBL'1 J
REMOVAL
1. Remove all gauges.
2. Remove all bulb holders.
3. Compress and withdraw retaining clip / heat sink and
voltage stabilizer assembly from housing Fig . 12-40.
4. Slide printed circuit to right and lift out Fig . 12-41 .
INSTALLATION
1. Reverse removal operations, ensuring that voltage
stabilizer contacts are located properly.
Figure 12-40
Voltage Stabilizer/Heat Sink and Printed Circuit Retaining Clip
Figure 12-41
Printed Circuit Removal
-~=:::::3----~~:~~":.'?J, --------~ ~-~
___.-;: : :. ---- ;(_~ "-~--8 -------~
-
~'
' --~ ~""!
~---
~
- _-:::::-----
;·
. '"'-,
,~/,--.,
/-.. ;;..c~ ~---.::A.
--
~ '--~' -
------
i
'"--- -~
--~:--l
BLE TO ENGINE
ASSENMESS REFER
/ .- ('
POSITIVE
/) ------,
---
MAIN WIRING HARNESS
REFER FIG . 12-51 ~ \
\ ~ --~
IT\
'-'
\ \:
I \1
:l
HAR
FIG . 12-44.- o LEA o ----_ ,\ I
~
~----"'-_, <----~--,. .~
-- ~ ~~':J~"'''j;
- - ~ ~~~~~~)
II ~
0- - - ~
~. "- ~
-' 7J~t_:/
-~_;_~ ~L , r·:?'- ;m
0 .,,
·- I \ <e ·11
~~~'~) ----_
~~--
- ~~-
1
~~~~ 11\. -----~
TIVE
\d ~....:: . . . . . . . ._
-~
l 1
i
--~'
' ----
;------; ~ c ------nctf:l~?-- --~-- ~<J./ -~

:_ .-~r_ ~/~ v /
"'-- _&[ - - } \ \ \"-- -
VIEW~
--lLJ "'! i _0:.-.--
[8]~ '//'2
=~~~
/f~ / _//_'
(~q<: ~ ~--/~ / / /
l ~ ~~-//
~ // -- - ROUTE GROUND CABLE OVER A/C
HEATER HOSES.
/ ~ ··--._ SURFA;c~ ~~ATTERY

ENGINE HARNESS \ / BATTERY
-~--~ _. -£-_.----.
.- -. .~-
&
AJ">
MATINGTERM INN
c CABLE & FREE OF POSTS
·~--c.
"\ \ I GREASE
~
MUST BE CELFEtRE ASSEMBLY
·Jf2, ' . -- ',·· B OW
' <f!!f ,._',,

~ · B .J~.j>H
1
II 0» c··:-, '. >'
""~~j - ~ '"' ' '. ~~

- ·- - INAL MUST BE BEL
1 , CABLE TERM F BATTERY POST
\ • C::.')v 1·. \ '• · ./1-:-.;av E·•. LOW PETROLATUM
I m
·-----tz~-
~'- - = 2<) 0
APeROX. fjl ui ..... TYPE1 r-
m
%~ , ABOVE HORIZ.
Q
::c
VIEW[g SECTION THRU TERMINAL ASM.
0)>
'......
N
I
Figure 12-42
~
Battery Lead Installation (L6) (0
-"'
I\)
I
U1
0
~
;:: ~-- 0:
m
r-
m
~
~j~-\\1u ~
~- I \~~ ~ ~ o':~;~;~·"?0.
NEGATIVE LEAD ll
MAIN WIRING HARNESS
REFER FIG. 12-51 ~ }
0
)>
~:, ·-. l r-
--~
~~ - ~
- . .''.,
&/ -- I I
'~~
VIEW IAI
CABLE PASSES ~ •
POWER STEERING PUMP BEHIND POWER .//
MOUNTING BRACKET WHEN FITTED STEERING /
PUMP WHEN FITTED
~~ / -- ///
--)~-- --~=~
/~,
J~ ~ ~--
\ I\ .
~(...___/
/
&l~
·~~
~'::;;:;~~ ..\-~
' ' I I POSITIVE LEAD
>~
CABLE TERMINAL MUST BE BELOW
TOP OF BATTERY POST. COAT WITH
~ -~}
PETROLATUM HN 1198 TYPE 1.
r; --~ ~\ ~\ MATING SURFACES OF BATTERY CABLE TERMINALS

~ ~j.Y
,'
AND BETTERY POSTS MUST BE CLEAN & FREE OF
GREASE BEFORE ASSEMBLY.
~\~~
INSTALL UNDER ENGINE

MOUNTING NUT & SECTION THROUGH
TERMINAL ASSEMBLY
VIEWIBI
Figure 12-43
Battery Lead Installation (V8)
/~-~
·, )~\ ~Pl~
//n_ :t;:;; :,., \
-~ -,__/' "'1fl \\\
-//
&l'\. DISTRIBUTOR VACUUM ADVANCE/~.~~~:-' '~-._,~ ~--~~~- ;~ 'u)
' SOLENOID
I
\(~-<(/.)<K...,~,.,.=-:>"
:~ ,J_ ' l'jr l~~~
- - ;(Jjt BROWN
III 'i
.-........._. DARK BLUE & BLACK LEADS \
\ ,, J~
. >-.. l
·\ . /
'- "--..j~ : ~!@. ~~~~6

I~,---~,
"' '~),- -
·r;,_u,)!;;::t
1- 1/f~ )' ~
'~?-
~ ~ w~. -- f}\1
VIE W ~ BOSCH
" ~1 j)
--~
.JLS,~~
r YG-··;;i.t·
J -~ ()) 0
/ ,(;~; ·'ll'
\
-, )J r.~y -~ ~ / BROWN
BOSCH •
~). ~EAD
~ SUPPRESSOR
r(,;:,~
·• """''~
(~P\. ,';-'/ Jr
'
m
b..
' ';:-.-Y_.~· --~

ffi-. ~-
~,~_, I.
., ' ·~~--"' I I ANTI DIESELLING SOLENOID./ "(' - ®.I
' /~4-"\_ ;)
~~ L DARK BLUE LEAD '• ~_;-\_;'),/ RED ·
~( ,_--~) LEAD
- . - __) -;.;,; v-· -.
I. ';£'-·--?
I ""'~~~DARK BLUE LEADS ~
'·
_L(-"·:- },A YELLOW LUCAS
t:. /),
~
~
~ suPPRESSOR
& PINK
~ f',
_ / ...
.. , I PINK L-EADS.
l ;; - - I ;;.,
LJ.::;;~
/;_
• /
J- ~
---
0 LEAD
-~ "~~
@ ,"" _
--.!
""'-"4 ,_, }")
~""'=~-:::--..-."'-
,- --
~ ~·<
'-- BVX, U16

[ DISTRIBUTOR LEAD ~,.--t,~y-
;:?/
?~~-~"<:;;: s~--o~
. """-o-'-
-' . ::1. ,.-
YELLOWLEAD
J}
S\~"-
~
\-"').-- •/-
"-.; \, ' (~
~"'
;c.;:~·~:-:"!:}__r-J~"
)J~
'- ' ~ lf
-,~~--"'- -~
~""----
· ~ -, ~- --(1 · "'~ I.'E>:!-u......

-- -'-'.:)
I -~
BROWN LEAD ', -· I \ \ I 4..-' \ ' -- . ,, l!r.::l.}._~
, --- I _., ,;;, ··,
I 1 ~ ' DARK GREEN -~ -'- '-·J<~'-! ""'1 '
' . <?~ -·
DISTRIBUTOR LEAD (~/ _;~-· ' . ~-- ::- _ "_- .r:Q.
~
,.;::.
~ . t'f~
r.-,
-'d/;.
-
e.-_:_~,.
- -
:-'_
-~
'1·
//
v.-
V _/
. BROWN LEAD
- - - VIOLET LEAD
BATTERY LEAD
LEAD
\:
f
f('!.· :
'
·,
. I
.
.·
'---\ v ~ v·
~~-~--~
I
1 •'
~'-oo ·
•?J/'5:.•
.'..f}l'
1
'fl'
',
'-
1 •
J
;
/
-"'
,_.::.-
'-
----- ()
m
_ ~ - / REFER FIG. 12-42. ---~ fok' r-
BLACK LEAD
MANUAL ENGINE ONLY. ~h-, m
&
'o"
2.4-3.2 Nm
ASSEMBLE CLIP VERTICAL _ _
& T:GHTEN BOLT
--- ---, "- ,- -
[6] .,._- Q
:a
& 61-68 Nm
0
A. 2,2-2,8 Nm '- )>
--- --·' '-""'
'......
1\)
I
Figure 12-44
U1
Engine Harness Installation (L6) ......
......
1\)
I
U1
1\)
m
r
m
~
:a
~
r
1 ORANGE/ 'L CONNECTIOI\1 TO

1 BLACK LEAD T.C.S. SWITCH
2 RED
LEADS
ffi 5, 4- II tYm
£
Q'
~
,'-.~
, TEMPERATURESENDER
VIEW [Q]
o~- ,~r~
20- 28 1ftn
,& 2,2-2,8/ftn BROWN LEAD-..

.
J ~ -L~---.
""· \~
')"--. '
'
'-·.1....\
\
\\.
\ ' )'
\~~-- / ·~
DARK BLUE LEAD FUSIBLE
LEAD ASSY .
__ . c n.) .'; /;/;
() 0 -..:
,/)/_-< ..
FOR INSTALLATION OF
\ ___ / -
~
FOR INSTALLATION OF \ !'-
- ~~ ·w
.~
BATTERY LEADS REFER WIRING HARNESS /
FIG.12-43. - - - ---./ BUIDE TUBE REFER FIG . 12-43 VIOLET LEAD VJEW(g
LUCAS ~
Figure 12-45
Engine Harness Installation (VB)
FOR INSTALLATION OF CENTRE DOME LAMP &
REAR QTR. LAMPS 8VX REFER
r FRT. DOME LAMP 8VK, 8VL
=--~
::::'- ~
--r-t·
' ........-===
~
·,
/:
I
'- ~ \~1 :_~)\:f?J

t-
I
\
.-, -- "
/ /
l1
(1 r-''\ ~tj
B
il :' \ "
sw.~!'ll 1
I . I
\JJ 'gl,.
,'1·
. \-.,- _, -.. ._ ./_ /

0 ' I
0_ _/- _,· i . )"'' ]\) · DOOR avK,8VL ONLY

~ ~ , A~~
, . _ . 1 __: •
-----~ ·~,....
~~-~_:',,
':::--.
__.::-
\.--_.J
[]FUEL TANK
<:_ K I - •
~~~ ~
,· .__
-·
-·SENDER /
~-~ UNIT
'
~
LQJ
--:o-~~~{ d '-- cf.fC.

r=-1 ~ _/ 1 - -" ~ /~
/ - ~\._/ ---· /. ff \ HN-1230 70,0 LONG-3 PLACES
0 \\ /'::: f
~
'? }if
REAR LA / / ·' //- \
r~~
-
._;
'·\
--:_
_...
- -~
_
/
--. \f ,
WIRING
/:
!. I
i
.
'
,.l;y
',//
j "t,
'~ --- / f'_/
~ ~~--::-- {- ~ / <~:)
.· SECTION A-A
~ -~ ---- J'~~,~ ///7;.--'
~
LICENCE PLATE LAMP ~ ------.::::_
-':::::_ I
/. ,.. ::;/'
/'\. / / /
//-
//- // /
' -- / 1. REAR SPEAKER REFER FIG.12-37.
/ 2. REMOTE CONTROL RR. COMP. LID LOCK REF. FIG. 12-52.
FOR INSTALLATION OF REAR LAMPS ,..-/ 3. HEATED RR. WINDOW REFER FIG. 12-54.
REFER FIG. 12-48. -------- ./ 4. FOR WIRING TO L.H. FRONT& REAR DOOR JAMB
.. _ ____.- SWITCHES REFER FIG.12-50.
FOR VIEWS [A][ID~[QJ[I][EJ REF. FIG.12-47 FOR VIEWS ITJ[§J[B]QJ REF. Fig.12-48
Figure 12-46
Body Harness Installation
......
1'\)
I
U1
~
--- --
REAR COMPARTMENT LAMP
- - - __ BROWN LEAD m
r
m
Q
::rJ
0
)>
r
REAR QUARTER
HARNESS ASM-BODY
LAMP LEADS 8VX
ORANGE TO
ORANGE/BROWN
FUEL GAUGE TAN LEAD WHITE TO WHITE
(IN SLEEVE)
VIEw lA I - WHITE LEAD HARNESS CLIP TO BE REAR SPEAKER LOCK RELEASE REAR
YELLOW/,BROWN LEAD COMPARTMENT LID 8VX
O~r~
_ ::
BLACK LEAD
SWITCH ~~) ~
DOORJAMB
I ,
RETAIN FUEL GAUGE LEAD
AS SHOWN WITH 90.0mm
VIEW [C)
. ~- LENGTH OF TAPE HN -1230
- 7 ~ '
ffi _ /
r~ 1
SEAL
REARDOORSONLY
~
~,~
~ _c~;r·~r~~
' ( ------------- --- /__-- ( BROWNLEAD
~ VIEW~ -
\ ~-. ~0- \~r
---------~-- _...--:::
RETAIN BODY HARNESS AS

SHOWN WITH 90.0mm
~~
,_ BLACK LEAD ~ I
\
\\ I \
!(------:.:" II :
II
/
~-::::--; ---
~;~I ~
--<
LENGTH OF TAPE HN -1230_
,_ ffi ,'.
\ &..Jl!:~ ~
\\\ \
~'"'I
0 <~(
~ ~~-
~
I /
I . (\j
REAR COMPARTMENT \.. 0 -<Jv
-- · v
LAMP SWITCH \._;!..---- REAR COMPARTMENT LAMP

VIEW [Q]
VIEW [E] VIEw lEI
Figure 12-47
Rear Harness Installation
------------------~E~LE:CTRICAL 12-55
c
0
iiii
'lii
.5
..
ftl
41
a:
I
I z
I $:
0
a:
aJ
"""
N
I
U'l
- SWITCH ILLUMINATION CONNECTOR
en
INSTRUMENT ILLUMINATION CONNECTOR
GREY LEAD m
r-
INSTRUMENT CONNECTOR
I ~ RETAIN OPTION HARNESSES TO MAIN
WIRING HARNESS WITH STRAP AS
~
:::D
l
APPLICABLE- 2 PLACES 0
l>
----.._ DWELL CONTROL CONN'S
r-
~ 2 WHITE & 1 YELLOW LEAD
FOR CONTINUATION REF. FIG. 12-25.
REF, FIG. 12-50
FOR CONTINUATION
REFER FIG.12-51
CONNECT WHITE LEAD AS

il\ ,/ SHOWN & BVK EXC CD4
'/
BODY HARNESS CONN.
/
~~
~LIGHT SWITCH ILLUMINATION
CONNECTORS
;.,, · 1 BLACK & 1 GREY LEAD
rl,
·~\ LIGHT SWITCH
, CONNECTOR
\ L TURN SIGNAL SWITCH
CONN (LEAD
COLOURS MUST
' MATCH RESPECTIVE \ OF 'WIRING DIAGRAMS' FOR
LEADS) FUSE LOCATION & USAGE,
STOP LAMP SWITCH CONNECTORS
L POWER ANTENNA HARNESS 1 RED & 1 ORANGE LEAD
CONNECTOR REF FIG. 12-39 \_
WIPER & DIMMER SWITCH CONNECTOR
FOR VIEWS [6),ffi] [Q .fQJ & Sec. 'A', Sec. ' B' . Ref . Fig. 12-49A
(LEAD COLOURS MUST MATCH RESPECTIVE LEADS)
Figure 12-49
Main Instrument Panel Harness Installation
FUSE PANEL ENGAGE THE (4) FUSE PANEL TABS IN SLOT OF
INSTRUMENT PANEL AND SWING IN DIRECTION
OF ARROW "A" WHILE PRESSING THE (2) LOCK
CLIPS IN DIRECTION OF ARROW "B".
LOCKCLIPS~ \ (A v I L TABS
LIGHT SWITCH ILLUMINATION CONNECTORS
B/~~w[g
~T
TAPE LEAD TO MAIN
PANE~
WIRING HARNESS
WITH GM 658M
INSTRUMENT
-OIL PRESSURE MAIN WIRING HARNESS. REFER FIG·. 12-49.
CONNECTOR 1 DK BLUE LIGHT SWITCH
LEAD LTACHOMETER & OIL VIEW[Q] CONNECTOR
1
PRESSURE LEADS
VIEW~
BEND TAG AROUND
MAIN WIRING HARNESS.
........_
CARRIER ASSEMBLY
STEERING SUPPO~~ / SECTION A-A

BRACK/ 1 ··~ SILENCER MAT.
- ~TRAP m
~. .......__ r
m
LOOP EXCESS BACK UP SWITCH LEAO
& RETAIN UNDER SILENCER MAT AS SHOWN
\
VIEW
IAI Q
:0
MAIN
WIRING HARNESS
ADDITIONAL HARNESSES
WHERE APPLICABLE ~
r
-"
1\)
Figure 12-49a I
CJ1
Main Instrument Panel Harness (Rear View) ......
......
1\)
I
U1
co
GLOVE COMPARTMENT LAMP CLOCK CONNECTORS FRONT SPEAKER m
CONNECTORS 1 ORANGE & r
1 BLACK LEAD-----------. m
~
::D
~
r
~I ' LH REAR DOOR JAMB CIGAR LIGHTER

/ SWITCH CONNECTOR CONNECTOR
1 WHITE LEAD
i
~lf\r·\-l'
~Jj
~-
I
• ••j,
l~
~·~
HEATER FAN CONTROL CONNECTORS EXC C60
I I I 1 GREY LEAD- 1
')~_\
1 TAN LEAD- 3
1 YELLOW LEAD- 2
__ 1 ORANGE LEAD- 5
1 BLACK LEAD- 4
'------· • TAPE HEATER FAN CONTROL LEADS I

- - TAPE WITH 50,0 OF HN-1230 EXCEPT GREY LEAD TO MAIN WIRING -& C60 1
2 PLACES AS SHOWN HARNESS WITH GM658 M.
REFER FIG . 12-47
Figure 12·50
Instrument Panel & Door Switch Harness Installation
- MAIN WIRING HARNES~CLIP
(2 PLACES)
RH. FRONT LAMP CONNECTOR . ..~
CONNECTION TO
FR. H / LAMP WIRING A A
HARNESS SECTION .-
TAPE WITH GM 658M

HEATER FAN CONNECTOR
TO MAIN WIRING HARNESS
AS SHOWN. & C60
~ ENGINE COMPT. LAMP

CONNECTOR
~
HARNE~·~
WASHER
MAIN WIRING
- - ~~~~
ENGINE HARNESS CONNECTOR
I:\ ~Vl~~·· '" ~ m

~ SCREW ~ ~-- --~ r
m
BRAKE FAILURE WARNING SWITCH
VIEW [6] BATTERY EARTH
2 TAN LEADS
~
::D
ffi 20-26Nm
~
r
"""
1\)
I
Figure 12-51 U1
Engine Compartment Harness Installation co
.....
1\)
I
en
Q
"\ m
r
m
REAR COMPARTMENT LOCK
REL EASE SWITCH
--------- Q
::r:J
~
r
/
~~
~
VIEW(g
--~· ~
~
\
~INSERTINTO
lf!
•J
CAVITY 13
STRAP TO HINGE
FUSE
ffi 2.4-3.4 Nm .
Figure 12·52
Remote Control Compartment Lid Lock Harness Installation
FOR CONTINUATION
_______ __/"""
REFER FIG 12-53 B.
FOR CONTINUATION
REFER FIG 12-53 B
I CARRIER ASM.
I
' ...--
m
I'""'
RELAYS
INSTRUMENT PANEL
m
~
2 PLACES CIRCUIT BREAKERS
2 PLACES
I :c
FOR VIEWS IBI [QJ [E) [f] & sEc lA) REFER FIG 12-~A VIEw IAI 0
>
I'""'
......
N
Figure 12-53 I
Power Operated Side Window & Door Lock Harness Installation

en
......
......
N
I
0')
N
EARTH (BROWN LEAD)
m
r
m
,..., Q
:::c
h
0
:t>
RETAIN HARNESS r
WITH MAIN WIRING EARTH (BROWN LEAD) )
HARNESS STRAP
VIEW~ MAIN WIRING EARTH

DOOR LOCK/ WINDOW LIFT HARNESS
CARRIER ASSEMBLY ~ ~AIN UNDER TANG
~ I DOOR LOCK/WINDOW LIFT HARNESS

r DOOR LOCK FEED (1 RED LEAD)
-- -~ MAIN WIRING HARNESS
CONNECT TO TERMINAL 'B'- RED FUSE PANEL LEAD
SECTION A-A
(2 PLACES)
r POWER OPERATED SIDE WINDOW FEED (1 BLACK LEAD)
CONNECT TO TERMINAL 'D'- PINK FUSE PANEL LEAD.
REAR WINDOW
'CUT-OFF' SWITCH
CONNECTIONS.
(3 BLACK LEADS)
I
)
'- FUSE PANEL
VIEW[Q] VIEW~
Figure 12-53a
Power Operated Side Window & Door Lock Harness Installation (Cont'd)
---
r
REAR R. SIDE DOOR SHOWN
HARNESS MUST BE PULLED THRU

GROMMET SUFFICIENTLY TO CLEAR
WINDOW AT ITS LOWEST POSITION
AS SHOWN
YELLOW/BLACK LEAD \ [';J__..-~tJ

BLACK LEAD~>~
VIEW~ ' ~_::.~ YELLOW LEAD

m
BLUE/RED LEAD
.y'--._ BLUE LEAD r-
m
VIEW [g Q
::0
0)>
•"""'
1\)
I
Fig. 12-53b en
(.,.)
Power Operated Side Window & Door Lock Harness Installation (Cont'd)
12_64 ELECTRICAL
r.n
r.n
w
z
a:
<{a
ILO
t:JN
~;
a:-
-~
:S:a:
zw
-~ '
1/
I
<{w
~a:
c
0
i
~
0 -=
U)
1--
<{z ::!Gl
U)
w ~ E
Ci
<{
z
a: "'
,....' J:
_./ w <{ ....
~ ~
\ ..J I"/" s,,
~
I-
z~
oc~
t:)N ·- c
a: u. §:
<{
w 0 -~
a:~a: ,-_-
~~--
> I :s:a:
>-w ~
liiGl
a:
0 w
z~
' -
,
Irn-"'~.:.__
Ci
2~ I I I .Tii4/~
ff.,. --- - - -. : _ ~~
I ow
(!)a: ~Gl
~~ jt:If~/A'~ ·· )
I
1
;t~
...J<{ II
i /I 'I!
I 1 :tl 1
· I /jil I l .:-,~ I' I'

J:
tii:s: / t!/f/,
zo '/
1
~ ~ I ,' 1// I I! I /I
I I \
I I
I /
I
/· \
\
~ :s: I I/;;
~/ I ' If/!'I
' I ,' /
1/1
I
I I /
I
I ' I'
I
I
I
'
\ dl~it(;/,,)1
I I ' I I I
'\~l/j;~%~~,
' 'I
/;II1/ I I I
'/1/1 /1/
"" ~:I(
(
Ci
<{
w
..J
I
~
<{
\'
w
ELECTRICAL 12-65
WIRING DIAGRAMS
INDEX
ENGINE ELECTRICAL & FEED CIRCUITS ................. 12-66 ELECTRICAL DOOR LOCKS & POWER WINDOW
INSTRUMENT FEED CIRCUITS ..................................... 12-67 CIRCUIT .............................................................................. 12-74
HEATER, WIPER & WASHER CIRCUITS .................... 12-68 CODES & LOCATIONS FOR 'VB' WIRING CIRCUIT
AIR CONDITIONING CIRCUITS ..................................... 12-69 DIAGRAM ........................................................................... 12-76
EXTERNAL LIGHTING CIRCUITS ................................. 12-70 'VB' WIRING CIRCUIT DIAGRAM ................................. 12-78
INTERNAL LIGHTING CIRCUITS ................................... 12-71
EXTERNAL WARNING LAMP & HORN CIRCUIT ...... 12-72
ELECTRICAL CONVENIENCE ITEMS CIRCUIT ......... 12-73
""""
I\)
I
en
IGNITION SWlTCH
en
• TRANSM CONTROLLED SPARK • COLD FEEL> .DISTR .'AC :-------, m
SWITCii SWITCH
r - -, AO'IANCE SOLENOID I 1 r-
( TRtl,iATIC "QR MANUAL I
r--~ m
·IIH
<I
J L-iiJ
I I
j _
!J:II2
~J~--u-P
SAC'Cbi!
~
'LUE~l
J _
y ,. T
t
BLACk~ .J, ANTI DIESELING
PINK BROWN
:::D
r-~~BLACkfi-eLACK-
If-] ~
1
ld--oRANGE-__c-oRANGE-tJ
BLACk--fl (;-BLACk_R_Ok
[j--
ruJ:l;
l1
~UE~
rI
Lf
SOLENOID
VIOLET
j]]:
REO
PINK
YELLOW
0
l>
r-
l _ _j
ORANG£
[6j
ORANGE
~
ii:
~ ijANGEPINK
eTc. s a DETENT SWlTCH r-+--, ----~'1-<l G PINK
( TURBOHYORAMATICI ·IIH I ORANGE -----,
L--~
DETENT SWITCJo< = CONTACT
D
( TRIUATIC) 1, I BREAKER
~:.~~j"L_I6BLACK CONNECTOR ~
~::;~CB--* ~ z
<
~ :::--.~TRIBUT!lj
L~~·~·
I IGNITION
~" TO TACHOMETER
REFER SHT. 2
l
,t-4-,
L __
1
j
I I IIII
1 12
PIN •PINk I":' ~ ~ u~ j
5-*
4
a-*
-* DISTRIBUTOR
DETENT SW.
AUTO TRANS . , .. o I 1
12 RfQ
r1 I
7~*
ISCYLJ
, . . . .,
I I
Ir - - l RADIO L J
RADIO INTERFER€NCE
INTERFERENCE _l
~RESSOR
L ~)
I II GENERATOR SUPPRESSOR =
r Lt_lj
.-----1--<1 •I I I 12 REO
:--&
c
•~m• r-,
~"' I'Q Ih I'"'"'"
~
~ ENGINE HARNEJ
,~ I ~"~'
CONNECT.ORl
II ~m"
I f I """
" "" ,
II "--'~J >
I
99
~ t_
u
I • -l- 0 0
>>
-~418~YLI 'z~ . •
1 ,....
L _ THESE COMPONENTS ARE NOT
'I 6'16CYLI B!ACK-o
1 """
EARTH ON """"'"'
14
e AVAILABLE WITH L14 & M40
~ ~ FUSIBLE LINK
(TRIMATIC)
rt-i-.
I I WIRE GAUGE 18( S.A.E) llljl£55 OTHERWISE SHOWN.
ilK) EARTH ON
L _ __j
NEUTRAL SAFETY SWITCH

I AUTO TRANS. ONLY )
* T.V.R.S . HIGH TENSION CABLE.
COLOUR: BLACK
RADIATOR
WIRE GAUGE 18 (S.A.E.) UNLESS

ITHERWISE SHOWN.
Sheet 1
ENGINE ELECTRICAL & FEED CIRCUITS
,- --~ PARKING BRAKE
.-------------'YELLUW~-- _~>--111• SWITCH
BODY HARN
CONN.
,.----+<1 111
TO R.H. TURN SIGNAL LAMP
<l REFER SHT. 7 OK BLUE
TAN----(
FUEL GAUGE
r--,
SEND,ER
t-[ __ ;< ~"""'"'
'
.=,.
TURN Sl&i'<AL ~WITCH

--l
I
I
I
OK . BLUE - ------ OK BLUEt I
~ ,.., LT BLUE ____....
LT BLUE-
TO L.H TURN SIGNAL LAMP

REFER SHT. 7 : I
L_j
' - - - - - - - LT. BLUE
ti--l
OK BLUE
TAN
OK. BlU E TAN
a
a
YELLOW I INSTRUMENT
illlll
TAN LT .GJIEEN PINK CLUSTER
BROWN I
II
, - - - - - - - - - - - - - - OK . GREEN LT BLUE TAN
TO IGNITION , - - - O K . BLUE - - - - -- - BLUE ------------f-<
BRAKE
SWITCH
REFER SHT.I
ENGINE
HARNESS
I
I
BROWN DK. GREEN I
FAILURE
~r---!--![>f--TAN ~ CONN III INSTRUMENTS OK. BLUE --=-EJ~ 1------f-
I---f- I
WARNING
SWITCH L:Y u c±±tJ CONNECTOR
BROWN
DK . BLUE I I
BROWN
~ "-'<lJJ:=t_J
L_ ~
,---(±)1 I
~
GENERATOR (E--BROWN BLACK
YELLOW
WITH TRAILER ONLY
m
---,
·HL_J~ ) - - O K GREEN J TO IGN-
COIL
REFER SHT.I ===
E F
9 1011
G
WATER TEMPERATURE
SENDER c:::Jc::lc::JO
56 7 8
=
070 0 0
==Gt-
0 ~ ~~~ PINK
m
OIL PRESSURE
r-1 c:::::lc::::::J c::l c::::J
--~--~----~--~ r-
SWITCH I SENDER
4 -1 ~
L_J
) - - O K . BLUE
m
TO ENGINE HARNESS
Q
REFER SHT. I :II
WIRE GAUGE 18 (S.A.E.) UNLE:SS OTHERWISE SHOWN
0
>
r-
..A.
1\)
I
Sheet 2 0')
INSTRUMENT FEED CIRCUITS .....
"""'
1\)
I
g)
TO GLOVE COMPT SWITCH / WITH TRAILER co
16 BLA CK
6
/ m
~-,;::~~TAN~:HlT
111
~16BO<>WN
~ • DWELL CONTROL SWITO-l
7 X W I T H O U T TRAILER
r-
HEATER
ILLUMI~bNY"""eLACK ~u- J !j}Q 0 0 I n
w 1 ao m
FAN
L
LOW~
I HHOH~
·~r
16 TAN
TO
REF SHT. 6 ~
__[
BROWN
I
z
l _ _.... ~
.._,,._ _ __ I, l A 8 C t:>
~c:::'c::::Jc::l l 0
D
.
E F G
Q
LT GREEN J:j I 2 3 4 ' = 9 1011 :::t'J
- ORAN GE
YEL LO W
OK GREEN
0...
t; !; c:Jc:::JCO
=
=<=>=
0
>
: :t~C ~ ~i~
c::l c::::J c:J 0
5 6 7 8 D 0
0 = r-
r+~rrr-1
FUSE
L.:. .:_·~_'_I
HEATER FAN
I I
-.. WHIT)ll
'-------+ 16 YELLOW ---+--___j
SWITCH
[_~ ~
I
r ~r>l--wHITE
6
ld- YELLOW
TO AUTO RETRACT
ANTENNA
REF. SHT. 8 r--l
• DWELLU~~NTROL WHITE
m I I
FRT. LAMPS WtP/WASH
® RELAY
YELLOW
I -+- I
I
i-1=:[:1 I I I
I +-"+ I
I -r-- I
L_...:::r-+ > - f - - - - - - 1 6 GREY
WIPER MOTOR I
I
LT BLU F
OK . GREEN
IL __ .J
I
~
OK GREEN
WINDSHIELD WIPER
__[
----!-<1 <-fl
a WASH~R SWITCH
~
OK GRH WINDSHIELD
BLACK U :'} ~ j WASHER PUMP
FRT LAMPS
WASHER CONTROL
0 ~~
® UNIT
~ ~ ~
VIOLE'T""'~
ri-F~ ::~~:~~ - - - - r ; - t ,
16 0 K GREEN
~
TO ENGINE ILLUM
LAMP
REF. SHT 5
il
,. -..I""" ... .~
VIOLET BLACK
TO RH. FRONT
LAMP
REF. SHT. 5
® WITH PROD OPT
ONLY
• WITH PROD OPT. OR
ACCESSORY I I I I
I
L
"'i
~..,1___J L H FRONT LAMP
3 I "' 1
L 3~31 _j R H FRONT LAMP
® WIPER MTR ® WIPER MTR
WIRE GAUGE 18 (S.A.E.) UNLESS OTHERWISE SHOWN
Sheet 3
HEATER, WIPER & WASHER CIRCUITS
,-,
AUXILIARY FAN
IT ~~ ~
D
D0 0
E F G
I I
rCOMPRESSOR CLU TCH EVAPORATOR INLET 1==== 1o=o 0 ===
= 9 1011
1r@-1?
L1r
BROWN_j ;
1
-----,
L-}-±-J
I
CONTRO L SW
r--;
li-" [
:::
6 7 8
~ -c= ~ l
0
I
=o=
===
12 1314
==
1==1 _j FUSE BOX
TT 160KBLUE
...... _______~
~
rN=T~:O SW. II toe
L__________________ B L A C K - - - - - - - - - - - - - - - - - -- --
~-------------------------------------------------------+-
~
EARTH Q'j
. RE LAY MTG.
1 r YE LLOW BLACK
II lJ 11±-l
I0=0 i~
z
w
I ., +--. 14 II
--
FAN
~ REL AY ! ~~+=: +=tl ~
r-·
Id
~
0
:=t •
4 I~ '---r--YELLOW c--38~:I
16 BROWN-+--f-----:
FAN
SWITCH
r~L
~ I I
~ -16LT.BLU E - C
MASTER
I ••
8 7 -1--> 16YELLOW
L_J
REL AY j->
~_:or ,---.
LT· BLUE
l ~
16 ORANGE
~·I
<---t-'
--T'
~--J
I
I
FAN
RES ISTORS
·-'"·~ ~
'----------------16YELLOW-----
BROWN ~YELLOW
0 BLACK
~----------16
"BLACK
YELLOW II I
m
iY'
OK BLUE
r-
m
;l±t.~ ,-J+-l. ~
L-~
2
I ' .JI
L__ -- _.J
L_ _ _ _ _ _ WIRE GAUGE 18 (S. A . E.) UNLESS OTHERWISE SH OWN ::rJ
~
AUX. FAN REL AY ALTER NA·roR FA N MOTOR ... ASTER SW.
'......
1\)
I
Sheet 4
C')
AIR CONDITIONING CIRCUIT CD
....&.
I\)
I
.......
11' • --ilt: 0
FUSE BOX
O TRAILER
(~--:t-> ~ H~
0
A 1:~;;~-n PARK
rom I ~ ~
i 0
1ao
EFt:>
BROWN
TAIL LAMPS m
lB
'--3-----' c • , r-
~ I = ,~000 ===I II m
1
=2-34 ..
0 0 9 10 II
·~"-'"~""
rr:1 TRAILER WIRING
~
c
- = -r< I 't-
Q
TU~N
CONNECTOR
• '9 E 'NN -
5-' ~'0 I = ==1
-= :rJ
,.I
TO SIGNAL > i - " ,_, 12 13
== i~ II.. 0)>
r
LAMP EARTH VIO LET = )
A H. TAIL LAMP.
REF SHT 7 16 VIOLH
z
r-
TAN~C[i ~ :t~) I""~

_./
i
..
VIOLET--£] rn
~
~-+
u
j[ <-0-- '""--f'l '"""" "' t - ' '1-

I
BLACk__. TO R.H. BACK- U~
LA MP
REF. SHEET 7
\/1I 16 BLACK -· z
~
•
:;:
,~. .. ~ ~
j "'" DC
~
\L-7'
• .• _ , "'"""
'"" _.. ""• """"
'
""
000< - · "
TO LIGHT SWITCH ILLUM .
REF. SHEET 6 ft:--\ LIC. PLATE
t-~} ILLUM . LAMP
t
ORANGE
z
~
~
d <-+-l z
;;
~
•
II~ ••v•oonw ,._,II 1: 0 )::+ :/
/'1~~·• o~LA«
f I+
""" ;::::::t I <-+
~
+[: __ .J
I
LIGHT
SWITCH
~
f
~+:::, ~;;.,-· v···"
BLACK
TO L. H BACK -UP LAMP
.I
l oLACk - -
REF. SHEET 7
L H. FRONT ~
LAMP CONN
16 LT BLUE/ BLACK ---f l

I
TO TURN SIGNAL
LAMP EARTH
REF. SHT 7
16TAN
16 LT GREEN --r I
TAIL LAh P
. ~
w
I
~
,-~ ~J
\. __-!--> [ f r - - - ---~·
I i
LJ
WIPER a DIMMER
SWITCH
L. H FRONT PARK
LAMP
Sheet 5
EXTERNAL LIGHTING CIRCUIT
:EADING LAMPS -
NO SWITCHES .
,- \
I
~
I
T
I
,;:---}t~l L~-,
FUSE BOX
2 g~ I
~
GLOVE COMPARTMENT TO CLOCK
LAMP REF SHT 8 R~AR
_,...-~ (8-0RANGE~ 2 3 4 c'"'c I c COMPARTMENT
_ ·•I"(_ _ 0RAN'7t )
u=
;b.., - ( _./
T~LINS1RUMEN1J I ~ 0ou I 0= 0
LAMP SWITCH
('--~l
~
I ' " "UMENTS coNN Q Q
19 ro" I I
~
I
·-~'~""f ~~
I I ~~ ~
~
s 7
~-~="j
nnnnnr' '"" ""'
4
~ ~
uLOVE COMPARTMENT
n0 n i
~L...04-~ ~~ ~=)
LAMP SWITCH ~ Q ,
8 00
"CJ ~ ~ DOME LAMP
GREY I~ i ! evx l
'~,"":~"""'
GREY
~J_j
l f - - - ----1-----+--BLACK:---------"
'"
••~ ro~•m••=;
GREY
l ri-t.
!~ ~z '~•
~
L__j
~
L.H CUARTER
RHEOSTAT
LAMP
.~ ~-~ ~
BODY HARN CONN
u
-~
~
4
J
z
~
~
~I1§ BV<ONL~l ~ ~
\
!~
GREY
..., .1,", ·.".. ORANGE
~
_/
ORANGE
~
~
<1 -
~
NGE.g]?-"'
j
> % c
'I ) l!i
~r---
~ 4 •
~ ~
~
~ ~
' /
I _) rr-
t ~
WHITE _ _,.
"'oo ""'" ' WHIIT rWHITE (DOEXC

ME. SVX)
LAMP
r WHITE _../
)
BLAC~
. -swlrcH ll.l.uM. - I R.H. QUARTE~
~1 ~~
' '
.
GREY -~ I ~-il
~-1 I
\~)
I
CIGAR LIGHTER
ILLUM.
J= ~~;L~~~~SOR ~UT-OFF
GREY_j I
\_
) CLOCK ILLUM
~i ILLUM
CONN
~-f,I
I ~~
~BLACK
~
~""'"1
0
z
~~
i
~
~
WHITE l/WHI'E~
'~'1)
0!SVXONLY)
,f-fl i SWITCH GR[Y \_)
LIGHT SWITCH
WHITE
~
~ ...6.., ~-
I I
\_}
iI
ILLUM.
r-r-Hffn FRONT I I I IREAR I I 1 I
r - r : = GREY L ____ j I
~
I
1_) FRONT)
1...1
I I
~~
I REAR
~~rb
A/C MASTER SWITCH
ILLUM
LIGHT SWITCH ...
ilil~- ~ ~ 1..
A/C FAN -
SWITCH r---l • ""
TO BACK- UP SWITCH
LH DOOR JAMB
SWITCHES
R.H. DOOR JAMB
SWITCHES
~-hBROWN m
1
"'"" ,~ '" IT-':;:h •5I ~ ' c-, :
REF. SHT. 7
r-
~ m
~ ~~ ~
I }
Ljl 1 I \_
~ WIP~ WIN~
I I
'"
~
nl ; \_)
=.
l- )
PS SWITCH Tv ·< rRACT - -
A I 'TENNA l
'V'
SWITCH
ILLU'vl
AUm TRANSMISSION
:::a
DRIVING ILLU
LA · M M S·."YIICH
• ILU.JM.l:.- -- _j INDICA TOR iLLUM.
0
)>
'......
1\)
I
Sheet 6
.......
INTERNAL LIGHTING CIRCUIT ......
....
1\)
I
.......
TO 1RAIU:.R 1\)
HIGH NOTE HORN LOW NOTE. HORN L . H TURN SIGNAL
( ACCESSlJMY \ ST0? LAMPS ==-~-CTBLUE
-1 m
I~~\
BACK- UP LAMPS LT GRE E N - - - - - - - -
r-
~
~~~, FOR TRAILER FLASHER RELAY
CONNECTION REF. SHEiT 2 /
EARTH
I€ ~~H~~~ I ! OK GREEN I I m
·•1f----t- ~
AU XILIARY
~
"I-+
'-. t-.:::_j
.m
.; 1-i . , uRN SIGNAL
'-. ;j;-::e:J
I FUSE BOX
•
--,STOP
__ /
1 LAMP
:c
L~DK _A__
TRAILER WRG -CONN.
n- .LJ
1401< GRHN
. • c
00 FLAS~ER RLY HA,Z AR~~t¢RN.
... 000
E F G r---------l-<1•1 • 1 r - - ,R .H.TURN
0
0\~ 0 ~
I SIG NAL
== === )>
.
~1::::::3 t::::3
- -""' LAMP
TO R H FRO l_j.34 -"'( 9 10 II r-
= -=
r t - L T GREEN
REFER
~~
lr1A I
u u
~
L~
ll- SLUE----1-..........
=== K
i =
~~
14 ORANG E - - - -
ITJ
=56 7 =8 0 °0~ !=; :4 [MJ ','ELLOW
c= = ===
OD~ARN
a:;:,.
u
c
~
~ 16 ORANGE
CONN. OK GREEN I I 'j> c
~
~
/--B~I6BLA ' -
1->1>- ~ 16
1"---1
BLACK -
TO FRONT LAMPS
WIPER CO NN.
REF: SHT 3
.
z
~
- L_
.~
~z
~0
~-
LTGREEN I __ / \
~- --~ ~LT Bl UE
-~ 1>-f-
-~ I H-
I ~-,
: :STOP LAMP SW.

R H. TURN SIGNAL OftANGE LTGREEN~~--,) BACK- UP
\-> 1>+- f-i:-_.J
LAMP
R.H FRONT I TO CLOCK
ORANGE_........
LTGREEN 0--/ LAMPS
LAMP CONN. REF.SH1;8

~+---L--,
I I
~-- "
.
u
c
lB--f--1
~
~
lB---t::. J BACK UP SW.
LH. TURN SIGNAL

LAMP ~-t'f-
'~:::,=tlt7[)
~ ~ ~~ 0t-<t-< m l lI
(,....- -~(B---Ll 8 L U E - f ?
, __ p,16BLAC<-----!? ~ 14BLACK~!·
VIOLET
OK BL UE
'--
t-<
OiJ
[i[] l
co'
OK GREEN-
YELLOW-t- .
t-BLACK--@-i\l•
c
-I?
L H. FRONT
I OK BLUE
LT. BLUE
[!]
o:::J
1
~
~
~
LAMP CONN. L 1 BLUE
/
[]] I 'I L.H . TURN SIGNAL
I I I I I I I
BLACK
L._._BROW N _ _ _ /
IIl
m I I LAMP.
l
\
[J. ;.;_-;. . ).. .!- .!- m 1
~J
[]] STOP LAMP
INSTRUMENTS CONN.
REF. SHEET 2
TO L H FRONT LA MP TURN SIGNAL
REF. SHT 5 sw.
HORN ~ [8-BLAC'<--(~r----- BLACK__j

BAR ~ HI· ROTARY
CONTACT
WIRE GAUGE 18 (S .A.E .) UNLESS OTHERWISE SHOWN
Sheet 7
EXTERNAL WARNING LAMP & HORN CIRCUIT
FRONT SPEAKER
r-..,
L J REAR SPEAKER ( PROD OPTION 6 ACCESSORY l
TI r --. FUSE BOX
LT· BLUE ! ~ I I
~ ~.
~n \
OK. GREEN
LTr 0 D0 D
iA-i i ~ I 0~0
1
~':; ~~ =-=
RADIO
YELLOW
LT GREEN
OK GREEN
!
LT. BL..IE
BROWN
rn==
BODY HARNESS
CONNECTOR
YELLOW
BROWN
J :~
ocoo
=
D0 0
00 0
=
0
oo=l
9 1011
OCD=>
0=0 1 ~ ~J! ••v•oLET---m-,.•L•cK--£J
BODY HARNESS
r-1
f--t- 1 Hiti~D
~ <---t-~WINDOW
GREY-----, CONNECTOR I
YELLOW ----------------+--+-_j ~
t ~
~
~
t
LT.ewUN TO SPL;. JOINT
REF. SHT-6
P.OWER·
0~ r--~
AN'TltaiU I I
..
SWITCR Is :s • 1 2 I
I·PROO. OniON 1
iittt ~
~
~
z
z
:i
i[b :::~·---,
~
~GREY--r- GlltEY--------1-- ORANGE

MAIN WIRING
HARNESS
~ORANGE ~TO DIMMER SWITCH
REAR COMPARTMENT
LOCK SWITCH
~JJ A:~:A
( PROD. OPTION 8 ACCESSORY)
BROWN
r-..,
TO I I
SWITCH li,LUM
it
Tr ~
REF. 6
TO SPLICED JOINT
t i
• BLACK~!
Ill REF. SHEET 6 I I ~
~
REAR COMPARTMENT
~
I
LOCK SOLENOID
,
~
I r-l
:::~::::. rt-f,
: ( PROD- OPTION 8
~~~
~
ruL~
L_ _j
i-1 l•z••••t
16 BR(1;1N
1' ,
rtri-T--,
BLACK
~ORANC E-----£)
__,___oRANGE__/-
Bl <-j
TO STOP LAMP SW fi<:F. SHT. 7
TO GLOVE COMPARTMENT LAMP

1
+-r __j
I
I
CLOCK -~
~
L_J
Ho·
ACCESSORY l
r-l.
,...m
POWER OPERATED
L __ _
L_ -~
I IL _ _ _ _jI REF. SHT. 6 m
ANTENNA
( PROD OPTION 1
POWER OPERATED At, rC:NNA
ELECTRONIC MODULE
HEATED REAR
WINDOW SWITCH ~
(PROD, OPTION 1
CIGAR LIGHTER ~- • .L
:::0
WIRE GAUGE 18 (S.A.E.) UNLESS OTHERWISE SHOWN 0
,...
)>
...L
1\)
I
Sheet 8 ......
ELECTRICAL CONVENIENCE ITEMS CIRCUIT ~
"""'
1\)
I
......
~
RH FRONT WINDOW MOTOR
DOOR LOCKS
R REAR P.H RR
WINDOW 5W CIRCUIT BREAKER m
~: ~ r BLACK/RE O
r-l
I I
1-l_J
DOOR LOCK MClUR
r-.,
I
' I
L I I
WINDOW MQ, .
.-,
!
~+-lj
I
,-l
I
Ll-1_)
I
r-
m
Q
DOOR
\ '
l. ACK /REO
LACK/ YEL LO W
,--
-
- -- - - - - ULACK / REO
1 6 BLACI': / YELLOW
4f :J_-t
l__=
'flti4YELLOW
14 BLUE - + - + - - - '
J Jl
0)>
L OC r
)
RELAY ·~ r-
- - GREY
- ""~ D=O D~fll
-, c~ OQD O~D \
z
~ c~ Da>O 0 NO
l
~
<=>
=:U I
"""fl-,
Q
f--<2 BLACI< / REO-
DOOR
~BLACK/YELLOW- I-
~
~ ""<=> D
LOCK
RELAY ~BROWN/WHITE
~ !
D==
BRowN/w""' DO?Re
K SW R H. FRONT c
~ ~ 1/U__j
I
ON)
D =
BROWN
BLACK I REO
~
,.. ~
~
3
z ~
BROWN
--@--11•
= =
REO •
• ~ ~ ~ \-c 0V 0 0
~ ARTHON DOOR
Bl
~ ~
~~
BLUE EARTH j STEERING
<
~
~
~
~ NER PANEL
cu Qr<lD 0
( I
YELLOW COLU BRACKET ~
.:
m >
I \-m DN D 0
! !
.
BL UE
--I D- 0 0
YELLOW
"'"' <
u
c::::Jc
~
r•~ Jj DOOR LOCK S W R. H.

I KEY I
NT m FUSE BOX
~~
I '
I
-+-+
---+--+ 14 BL UE
I PWR . OPER
=======--~-~
PWR OPER SIDE
I · ~ 14 YELL OW r- 'l WINDOW
WINDO W SW.
I I0 ---r--> IZ BLACK
<L: _
I CIRCUIT
_J BhEAKER
I ! I ) 14 YE LLOW
14 B L UE
t ·~ 16 BLACK / RE D
f'
~ ·~ 16 BLACK/YELlOW
L :_ -:::j----4 1£ BROWN
! ..
u
.:
~:::~· 11
~
~~
EARTH ON TUNNEL COVER
PWR.OPER .
r--, WINDOW
!;=:= 14 BLUE
ri48LACK
<--c" _
I OVERRIDE
..J SWITCH
[]~~·~~
cttJ
ri-'h ~-T, rT-1-,I r\-\., rl'ftt4J
I I I I I I I I I
L_..J L_..J L_..J L ___ .J
L_ - '
DOOR LOCK WINDOW MOTOR DOOR LOCK WIN DOW MOTOR L H REAR
M070R MOTOR WINDOW SW
WIRE GAUGE 18 (S.A.E.)
LH FRONT L H REAR UNLESS OTHERWISE SHOWN
Sheet 9
ELECTRICAL DOOR LOCKS & POWER WINDOW CIRCUIT
ELECTRICAL 12-75
NOTES
•
-
•
INSTRUMENTS SENSORS MOTORS Lamp Bulbs Con't
I
"""
1\)
I
......
Code Name Loca- Code Name Max . Loca-
c:n
tion Amp. tion m
r-
I 1 Alternator Indicator
(Bulb) 48
SS1 Brake Fail. Warning 48 M1 Horn ( 1 or 2) 6.5 39 B10 Dome Lamp (1) 0 .83 41 m
12 Clock 45
SS2 Parking Brake Warn 1
SW. 0.2 49
M2 Antenna Motor 5.0 32 B12 A uto Transm. Ind.
Ilium.: !) 0 .1 154 ~
13 Brake Fail Warning SS4 Cc:d Feed SW
M3 Radio/Tape Play , E8,
Speakers B 13 lnstr. Cluster Ilium.
:a
Lamp 48 (Exc. L 14 & M40~ 52
M6 Heater Fan Motor 8.5
78
63
(40FF) 0.1 28 0)>
14 Parking Brake
Warning Lamp 49
SS5 Trans. Contr. Spark SW.
(Exc. L 14 & M40) 52 M8 Windshield Wiper Motor 2.5/5.0 93
B14 Dwell Control SW
Ilium. (1) 28
r-
16 Voltage Stabilizer 53 SS6 Coolant Temp . SW. M9 Washer Pump Motor 3.8 95 B15 FRT Parking Lamp (2) 0.33 22
(With (116) 59
17 Voltmeter 47 M11 Air Cond. Fan Motor 12.8 71 B16 Tail Lamp (2) 0.42 23
SS7 Oil pressure SW.
18 Coolant Temp . Gauge 54 (for lamp) 0 .3 60 M12 Air Con d. Auxiliary B17 Licence Plate Ilium.
Fan Mot. 8.5 75 (1) 0.83 23
19 Oil Pressure Gauge 55 SS8 Neutral Safety SW. 7
M13 Pwr Oper. Side 110/ B23 RR Comp't Lamp (1) 0.83 40
I 10 Fuel Gauge 56 SS9 Back-up Lamps SW . 151 Window Motor 117
B25 Radio Ilium. (1) 28
I 11 Tachometer 57 SS1C Stop Lamps SW . 8.0 44 M18 Starter Motor 510.0 5
B26 LightSW Ilium. (1) 0.1 28
I 12 L.H . Turn Sign SS11 Air Cond . Aux . Fan M19 Ignition Coil 3 .7 8- 9
lnd (Bulb) 100 Temp. SW. 74 B28 Cigar LTR Ilium. (1) 0 .1 28
M24 FRT Lamps Wiper
I 13 R .H . Turn Sign SS1" Air Cond . Evap . Inlet Motor 8.0 18 B29 Back-up Lamp (2) 1.75 151
lnd (Bulb) 101 Contr. SW . 76
M25 E L Door locks motor B30 Heat RR Wdw SW.
I 14 High Beam lnd (Bulb) 24 SS1~ Transmission Detent SW. 152 (30FF) 8.0 122-7 Ilium. (1) 0.1 28
I 15 Oil Press. Warn Lamp M27 Distr ., Cont. Break., B31 Clock Ilium. (1) 0.1 28
(Bulb) 60 RESISTORS, Spark Plug - 8
I 16 Coolant Temp .
RHEOSTATS B32 Engine Comp't
Ilium. (1) 0 .83 22
Warn Lamp 59
Code Name Loca- B33 Auto Retr. Ant.
tion
I 22 Turn Signals Warn LAMP BULBS SI(V . IIIum. (1) 0 .1 28
Lamp (Trailer) 97
E1 Heated RR window 84 B35 A i r Cond. Master SW.
Max . Ilium. (1) 28
E2 lnstr. Ilium. Rheostat 0-17 27 Code Name Loca-
Amp . tion
B36 Air Cond. Fan SW.
E3 Air Con d . Fan Ref. Ilium. (1) 28
Resistors Circ. 71 82 L .H. RR Turn Sign
lnd (1) 1.75 98
CAPACITORS E4 Cigar Lighter 1.25 82
83 L.H. FRT Turn Sign
lnd (1) 1.75
Code
C1
Name
Radio Interference
Capac it. Loc.
E5 Oil Press Sender
(WITH 19)
10.0-
180.0 55
84 R.H . FRT Turn Sign
lnd (1) 1.75
99
102
[0 ELECTRONIC MODULES
E6 Coolant Temp. Gauge 40.0-
Suppressor 0.5MF 10 (WITH 18) 282.0 54
85 RH-RR Turn Sign Code Name Max . A . Loc.
C2 Radio Interference lnd (1) 1.75 103
E7 Fuel Level Sender 35.0-
Suppressor 0 .5MF 2
331 .0 56
B6 High Beam (2) 5.0 25 N1 Dwell Control Unit 91
C3 Primary Voltage
E8 Speakers Balance
Capacitor 10 87 Low Beam 4 .58 26 N2 FRT Lamps Wash
Rheostat 0.0-
72.0 77 Contr. Unit 17
B8 Stop Lamp (2) 1.75 44
E9 Ballast Resistor 1.8 6 N3 Auto Retract Ant.
B9 Glove Box Ilium. (1) 0.42 46 Contr. Un it 32
-- --- -
I
RELAYS. SOLENOIDS Switches Con't FUSES Con't
Code Name Max . Loca- Code Name Cod! Name

Amp tion
R1 Horn Relay 0.14/ 38 S15 Dwell. Control SW . Wiper Motor I

86
Flasher Circuit
R3 Anti -Diesling Solenoid 0.45 50 S16 Windshield Wi per/Wash SW . 93 Dwell Control
5 WIP /WASH Mot. 16A
R4 Distr. Vac. Adv. S18 Turn Sign . & Hazard SW . 100 FRT . LPS WIP/WASH 94 I
Sol. (Exg. L 14 & M40) 2.3 52 Relay
S20 Air Con d. Master SW . 71
R5 Transm ission Detent. Cigar Lighter
:
Solenoid 1.10 152 S21 Air Cond . Fan SW. 70 6 Heated RR Wdw 25A 82
R6 Flasher Relay 4.46 98 S22 Dimmer & Flasher SW. 25 Heater Fan
7 Ant. Contr. Unit 16A 64
R7 Air Cond . Compressor S24 Glove dox Ilium . SW. 46
Clutch 76 8 Rad io 3A 78
S25 Door Jamb SW. 41
R8 Air Cond . Fan Relay 130.0 68 9 lnstr. & Controls.
S26 Light SW 25 Ilium. SA 28
R10 Air Cond . Aux . Fan
Relay 0.14/ 30.0 74 S29 Pwr. Oper . Side Wdw. 110/ Back-up Lamps
SW. (1 WAY) 115 10 Detent Solenoid 8A 151 i
Auto Trans . Ind. Ilium.
S30 Elec. Door Locks SW
R12 Starter Motor Solenoid 11 .0 6 (Button) 131 Emiss . Contr . System
11 Instruments SA 50
R13 RR Comp't Lock S32 RR . Comp't Lock SW 149
Solenoid 149 12 Air Cond . Mast. Relay SA 66 !
S34 Ignition SW. 17
R15 Hazard Flasher Relay 100 13 RR . Comp't Lock 16A 142
S39 RR. Comp't Lamp SW. 40
R16 E L Door Locks Relay B Air Cond . System 25A 67 I
(2 off) 0.5/ 50.0 135 S40 Pwr. Oper. Side Wdw.
Overide SW . 106 c Air Cond. Aux. Fan 15A 75
R17 Air Cond . Master
Relay 66 S45 Pwr. Oper. Side Wdw. D Antenna Motor SA 31
SW. (4WAY) 112
R18 FRT Lamps Washer SOL 2.0 15 E Antenna Motor SA 33
R19 FRT Lamps WIP/WASH FUSES !
Relay 1.0/ 15.0 17

Flasher Relay (Trailer)
G P/ 0 Side Wdw . Motors Ref. I
R23 96 No. Circu its Se rved Rating Loca- Dwg . 111
tion
H E L Door Lock Motors Ref .
SWITCHES Light sw. Dwg . 138
1 Antenna 25A 22
J Fusible Link 8
Code Name Max. Loca- Horn m
Amp. tion Hazard Circuit r
S1 Horn Button 3'
I l I Dome Lamp
.' l ear Comp't Lamp
16A 40 m
S2 A uto Retract Ant. SW 10.0
- f- Stop Lamps
RECTIFIERS Q
Clock :a
S11 E. Door Lock SW . (Key) 127
I Gl o•Je Comp't Lamp BA 45 FodJ Name Max.
A.
Loca-
tion 0)>
S13 Heated RR Window SW. 84 t=RT Par king Lamps
S14 Heater Fan SW. 63

Tail Lamps
FRT. Lamps WIP /WASH 16A 23
D1 A i r Cond . SW.
Protect Diode 3.0 77
r
-- ---- --- - - ·- - ~
1\)
I
......
......
•
12-78 ELECTRICAL
SYMBOLS USED IN
WIRING CIRCUIT DIAGRAM
(Opposite Page)
0 FIXED CONTACT
e FIXED CONTACT
(UNDER POWER)
_/ MOVABLE
0 CONTACT
/-/SIMULTANEOUSLY
cf Cf MOVABLE CONTACTS
;!:;r FUSE BOX LOCATION

~ FUSE
T
CIRCUIT
BREAKER
CONNECTOR BODY
WITH FEMALE
TYPE TERMINALS
CONNECTOR BODY
WITH MALE TYPE
TERMINALS
SIMPLIFIED END
VIEW OF A •
CONNECTOR BODY
RED=LOCATION
& COLOUR OF
A LEAD
SIMPLIFIED VIEW
OF AN ELECTRICAL
( C --:- I COMPONENT
I (WITH 2 MALE
€ L ~
I~
. -------
.
EARTH FROM
COMPONENT TO
. VEHICLE BODY
~
EARTH THROUGH
EARTHING LEAD
~ TO VEHICLE
ALL SWITCHES
SHOWN IN 'OFF'
POSITION
..
FUSIBLE LINK
I • I • tc=Jr----1~------------------.-----------------------------------~~---------*
S34.
~ §] @]
1
---
B11 I I IB2
,..........
A~
I 1I TOS25(41)
II~
TO FUSE No. 7 (64)
s I \
'i:j I IE~ 11\\

~
~
12
I
GEN .I
~'/: \\ I I
I I
\
\
-
3
4 5
N3
[>
1 2
__ksJ~o
TO R15(100
fl R~7
I
30 S26 131
-Gl
~
(/)
-i 0
z ::::1
~
)> )>
( QO
c
;
r-
g
:z
~ I /Q g r-
0
(")
;><;
SS8 4
R19
"" 0
:WTOM9(95)
l~s2
TERY--
~ ~--H--_.'
r 8 @]
5
u D
1ni fEl PART OF Sl t C

•
C1 L__ 0\
~ EJ ANT fv'IOT . l
R12 85
~
[>
31 31BS I N2
31BMt 15
1
1
9f Ml
/J
START
~~B
S22 M2
'--+--
458A
M18 E2
.--- ~3A
~ "
~~ ~ ~!' ~;:
111~
Ml27
R18 311 M24

B1
B3 11 B2~
.,ff~ .~ ro s26da1
M231 I I =c3
~~2~
B 3
'( j-~
B 4 S39 S25
B 5
'"' '"' ..1.. '"'

~ A
1""'\.
VV
th th .th..
VV"'.J · ~
£"\. ,....... r"
~36,.. r"\th.l""'\.1""'\.
123456789
v
__
v v
_
u 1 1 2
"
3 4 5
123456789 123456789 12 3456789
10 20 30 40
Q~ PART OF PART OF irl
~~ A / C HARN . A/C HARN .CJ
TO N3 (32)
TO M27 (8)
l
\lo . 7 (64)
® 11
R1'8 ..... 3
17 4
- TO R15(100
2
\ '
~
520
2 €~ M6
'To
~~~. 0
86L
- Rl 85 87
17
R1oun
~ 85 87
I3 G9 0~ F 1,.1}{;:~
14 18 I 10
'
b D
52
I [>
t 19 I 11
PART OF s1 'c SS1
ANT tiiiOT.
9
SS2
:> (
_'p I
~
SS< SS13
Ml
~ (
2 o\
SS4
E6
I~ E7
810
Q~Q9 Q~
(
Q? iJ)
82: ~8_1 89 ss~>\ E5
~ ro 526(28)
~ 524
I~ ' ()- L
01
525
v v v v
3456789 123456789 123456789 123456789 123456789
40 50 60 70
'VB' WIRING CIRCUIT DIAGRAM

hi r.-:Jiol PART OF PART OF fr1
§;
L:J ~~ A / C HARN . A / C HARN .LJ @] 0
.r~
~
TO FUSE No. 2. (40)
RfHB1
/7 ' B
R6 R15 r---
L L
d
Q
(
8.§1_ 1fo ~ S40
~
R10~ S13
R23149Ah
851 187
L-
~ M~
(L.H.FRT .)
~•
E4
,x:~
I y, I"\
I p 11 2
~
(
•
E1
(P) nK L
~
.
~l
I SS13
S29
(L.H.RR)
~
S18 3
SS11
r<5]
~
. 31B ~1 ~
L..J
4
,"11""-c2J~
TOR19(17)
B20~ ® 1®
1 12
113$
85
M13
(L.H . RR)
I M9
M11n R7
£;>
B3 IB4
01
I 4
eeleleelee I I I
5 6 7 8 9
70
1 2 3 4 5 6 7 8 9
80
~.l.-.l-~--.l..-.1.~
uouuuuuu
123456789
90
"to
123456789
100
,...... ,.....
123456789
-"" -,..... ,..
11
-
.
G H
( (
10
I 1 I 5
S11 0
)
I (;l
() ( j
t- - - - S30
)
)
IO
I-- S32
98432176 \
;r_
SS9
LQM13~ rv125 85
R16
t:i
86 ~
~ . FRT . ) ,.....-
-
.___ (R .H.FRT.)
..---'L_
.H.....
. R_R_)- "-'-";£
-........-:: ==-30;.;...;., 30
SS19
9
8
42 5 42 5
85["]
30A Yl
86 l
I( - II I( ·- M25 M25 ~------~~~
87--+- 30
c~
~.RR) I3 <)1 I ( 61 T~.9H. RR)
3
(R .H. RR) '~ .. H. FRT) R
16 R13
c~
3 M13
D ~
R5
~- RR) (R.H. RR)
829®
89 123456789
--
123456789
,_, _____ '"'
1 23456789 1 2 3 4 5 6 7 8 9 ..... 1 2 3 4
110 120 1~ 1~ 150

Holden Commodore VB

Uploaded by

Copyright:

Available Formats

Holden Commodore VB

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Holden Commodore VB

Uploaded by

Copyright:

Available Formats

HOLDEN

BODY , SHEET METAL,

Thi s Manual co ntai ns desc ripti ons, specifica tion s and

Di ag nosis, main tenance , maj o r and min or se rvice ope rat-

used in oth er G MH vehi cles, no maj o r se rvice repair and

Th e sec ti on Ind ex on this page enables th e user to qui ckly

locate any desired sec ti on . At th e beginning of eac h sec ti on

of eac h maj or subj ect within th e sec ti on.

Summari es of Spec ial Too ls, wh en required, are found at

avai lab le at th e tim e of publi ca ti on approval. Th e right is

EFF ECTIV E JANUARY, 1979

SERVIC E MA NUAL NO. M38145

GENERAL MOTORS-HOLDEN'S SALES PTY. LIMITED

CO PYR I GHT - GE N ERAL MOTORS - HOLDE N 'S SALES PTY. L TO.

MODEL AVAILABILITY & BASE EQUIPMENT

WHEEL TREAD TREAD TURNING

ENGINE DESIGNATION 2.8 5 3.3 4.2 5.0

COMP. RATIO : 1 9.2 9.2 9.4 9.4

(M) MANUAL TRANSMISSION (S) SINGLE EXHAUST

TRANSMISSION NUMBER LOCATIONS

VEHICLE SERIAL NUMBER Turbo Hydramatic

BODY & OPTION IDENTIFI CAT ION

SAFETY COMPLIANCE - FRONT PANEL

THIS VE HI CL E WAS MANU FACTURE D BY

Figure 0-3 Figure 0-4

1. DESIGN RULE COMPLIANCE LETTER

VEHICLE SER IAL NUMBER STAMPED

JUMP STARTING WITH AUXILIARY (BOOSTER)

CAUTION: Any p rocedure other than the above could result

VEHICLE TOWING a minimum of 1 Ocm from th e ground , care should be

6 Cylinder Engine 8 Cylinder Engine

ENGINE LUBRICATION & SERVICE

MAINTAINING OIL LEVEL CLOSED POSITIVE CRANKCASE

CRANKCASE DILUTION AIR CLEANER

AUTOMATIC TRANSMISSIONS LUBRICATION & SERVICE

LUBRICATION & MAINTENANCE INTERVALS & DETAILS

Part Name Lubricant

Doo r Loc k Strik er Bolts

Front Doo r Loc k Cylinders

CONSOLIDATED LUBRICANT RECOMMENDATIONS

Front Suspension St ruts . .... _ . _ . ... _ .. __ .. ... . . Flu id to GMH Specification :

CONSOLIDATED LUBRICANT RECOMMENDATIONS (Cont'd.)

Part Name Lubricants

* Trade Mark of GM Corporation

LOCK - INSTRUMENT PANEL

PAD - INSTRUMENT PANEL UPPER

INSTRUMENT PANEL COMPARTMENT 0

PAD- INSTRUMENT LOCATION INSTRUMENT PANEL LOWER

SUN VISOR INSTALLATION

' \ _ VISOR & PIVOT ASM

REAR COMPARTMENT LID

HINGE SPRINGS- REAR COMPARTMENT

LOCK CYLINDER - REAR COMPARTMENT

4. Disengage outboard ends of torsion springs from hinge

LOCK - REAR COMPARTMENT LID Figure 1-13

LOCK STRIKER - REAR COMPARTMENT

FRONT AND REAR DOOR ASSEMBLY

HANDLE- DOOR WINDOW REGULATOR

Sheet steel - 2x24x200