VENTILATION & HEATING 2A-1

SECTION 2A

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(--,
) VENTILATION & HEATING
INDEX
Ref. Subject Page Ref. Subject Page
1. GENERAL DESCRIPTION .............................. 2A-1 2.3 BLOWER MOTOR HOUSING ASSEMBLY.. 2A-8
1.1 MANUAL CONTROLS .................................... 2A-4 Remove.................................................... 2A-8
Demist ...................................................... 2A-4 Reinstall .................................................. 2A-11
Floor ........................................................ 2A-4 2.4 HEATER ASSEMBLY ...................................... 2A-11
Vent .......................................................... 2A-4 Remove.................................................... 2A-11
Bi Level.................................................... 2A-4 Reinstall .................................................. 2A-12
Recirculated............................................ 2A-4 2.5 HEATER CORE AND PIPE ASSEMBLY...... 2A-13
Off ............................................................ 2A-4 Remove.................................................... 2A-13
2. SERVICE OPERATIONS ................................ 2A-5 Reinstall .................................................. 2A-14
2.1 MODE SELECTION, TEMPERATURE 2.6 WATER VALVE ASSEMBLY - HEATER
CONTROL AND BLOWER FAN SWITCH CORE ................................................................ 2A-15
ASSEMBLY ...................................................... 2A-5 Remove.................................................... 2A-15
Remove.................................................... 2A-5 Reinstall .................................................. 2A-16
Reinstall .................................................. 2A-6
2.2 BLOWER MOTOR ASSEMBLY .................... 2A-8
Remove.................................................... 2A-8
Reinstall .................................................. 2A-8

1. GENERAL DESCRIPTION
The ventilation and heating system featured on VL Series Models allows air entering the system via the grille at the rear
of the engine hood, to pass through the blower motor housing and heater assemblies and to be heated, mixed or

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allowed to remain at ambient temperature, as required. The air then enters the passenger compartment through the
centre and/ or side ventilator outlets, or through the demist or footwell outlets (refer Fig. 2A-1) depending on the position
of the mode or temperature control levers illustrated in Fig. 2A-2. Fig. 2A-2 also illustrates the air flow within the heater
assembly at the various mode settings.

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2A-2 VENTILATION & HEATING

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Figure 2A-1

BLOWER MOTOR
SWITCH

TEMP. MODE

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,-s..,..;,
I =" MODE
II � CONTROL
LEVER
TEMPERATURE
CONTROL
LEVER
DEMIST
HEAT/VENT CONTROLS

VENT OFF NO AIR FLOW

Figure 2A-2
 VENTILATION & HEATING 2A-3

On sedans, air from the passenger compartment ex­

hausts through ventilator outlets located behind the right
and left side rear drip mouldings, illustrated in Fig. 2A-3.
On station wagons, the air is exhausted via the edges of
the rear quarter inner trim panels, into the roof, then out
into the atmosphere through tail gate hinge pockets.

Figure 2A-3

The volume of air from the outer ventilator outlets (refer

Fig. 2A-1) is controlled by a regulating wheel below the
outlet inserts illustrated in Fig. 2A-4. The air flow can be
directed as required by tilting and/ or swivelling the
ventilator outlet inserts. To stop the air supply from the
outer side vents, rotate the regulating wheel to the right.

NUT
SPEAKER GRILLE
rLEFT SIDE
(2 PLACES R/L)
�11111!';:=--/ SPEAKER GRILLE
RIGHT SIDE

OUTER UPPER
AIR OUTLET

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SECTION 8-8
(4 PLACES)

INSTRUMENT PANEL LOWER L/SIDE

Figure 2A-4

The heating system utilizes an air mix principle where the

temperature of air entering the passenger compartment is
controlled by a temperature lever illustrated in Fig. 2A-2
which operates the air mixing door. This regulates the
("- ) volume of air passing through the heater core.
2A-4 VENTILATION & HEATING

The temperature, mode and blower motor control

assembly illustrated in Fig. 2A-2 consists of a four speed
fan switch, which regulates the rate at which forced air is
delivered into the vehicle through the various outlets. The
left hand lever regulates the temperature of air entering
the vehicle in all modes and the right hand lever is for
selecting the particular mode required.

1.1 MANUAL CONTROLS

The mode control lever has six positions:

DEMIST @
In this position, the air flows onto the windscreen through
the demist vents on top of the instrument P?1,nel.

FLOOR \�
In this position the main air flow is directed to the floor
outlets with a small amount going to the ·demist vents.

VENT :.:Q:,
This setting directs all the air to the centre and side
vents. The air flow and direction can be individually
adjusted at each vent.

Bl LEVEL --
�
This position directs air to the centre and side vents as
well as to the floor vents.
)
RECIRCULATED �
This setting directs all recirculated air to the centre and
side vents. In this setting, no outside air is admitted via
the ventilation system. This setting is only recommended
for short periods when driving in dusty or smelly
conditions with all the windows closed. Return the mode
lever to one of the other settings as soon as conditions
permit.

OFF
In this position the fan is switched off and no outside air
is admitted via the ventilation system. This setting is only
recommended to be used for short periods when driving
in very dusty or smelly conditions with all the windows
closed. Return the mode lever to one of the other
settings as soon as conditions permit.
NOTE: The blower motor fan automatically switches on -....,,,_
when the mode control lever is moved away from OFF
position. Fan speed can be then regulated to suit.
 VENTILATION & HEATING 2A-5

2 SERVICE OPERATIONS
The non air conditioned air ducting on VL Series,
illustrated in Fig. 2A-5 is polyethylene tubing with mating
indentations and protrusions which retain the ends of the
ducting together.

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OUTLET DUCT
LEFT SIDE

HEATER ASSEMBLY
BLOWER MOTOR
HOUSING ASSEMBLY BLOWER MOTOR HOUSING
TO HEATER ASSEMBLY DUCT

Figure 2A-5

Should any of this air ducting be disturbed during

instrument panel operations, it is essential to ensure that
such ducting be correctly reinstalled so as to prevent
possible air leaks at these joints and connections.
Removal of any of the ducting except the right side
upper, necessitates removal of the left side instrument
panel (refer 1.4, 'Front End', Section 1A, in this Volume).

2.1 MODE SELECTION, TEMPERATURE

CONTROL AND BLOWER FAN SWITCH
ASSEMBLY

REMOVE
1. Disconnect battery ground cable.
2. Remove left side instrument panel lower trim
assembly (refer 1.1, 'Front End', Section 1A in this
Volume).
3. From under left side of instrument panel, disengage
i ) clip securing temperature cable to heater assembly
\_�__/' (refer Fig. 2A-6, View B) then remove looped end of
cable from temperature control lever.
 ,�\
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FOR CONTINUATION REFER SECTION 12F

HEAT ANDVENT
CONTROL ASM.

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VIEW[!]
m
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FULL FORWARD WITH , 1 z
TEMPERATURE LEVER HOSE NO. 4
IN DOWN. POSITION Ao
VIEW 00 :c
m
BEFORE SNAPPING CABLE IN, POSITION MUST BE
FULL FORWARD(AS SHOWN)WITH VIEW� -I
TEMPERATURE LEVER IN DOWN POSITION.
ASSEMBLE NUMBERED HOSES TO
-z>
CORRECT PORT ON VALVE C,
CAUTION NOTE: NO KINKS IN HOSES
VIEW [Q] I\)
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fjgure 2A-6 �
2A-8 VENTILATION & HEATING

2.2 BLOWER MOTOR ASSEMBLY

REMOVE
1. Disconnect battery ground cable.
2. Remove left side instrument panel lower trim
assembly (refer 1.1, 'Front End', Section 1A in this
Volume).
3. From under the instrument panel, disengage the
blower motor to main wiring harness connector, then
supporting the blower motor, remove the two screws
securing the cover and motor to the blower housing
(refer Fig. 2A-7). Remove the motor.

REINSTALL
Reverse removal operations.

BLOWER MOTOR
HOUSING ASM.

Figure 2A-7

2.3 BLOWER MOTOR HOUSING

ASSEMBLY

REMOVE
1. Disconnect battery ground cable.
2. Remove left side instrument panel lower trim
assembly and the instrument panel compartment
(refer 1.1 and 1.3, 'Front End', Section 1A in this
Volume).
3. From inside the engine compartment, remove the air
inlet deflector and the screw attached air inlet seal
ring secured to the left hand side of the plenum
chamber, as illustrated in Fig. 2A-8. Remove the ring
assembly.
 VENTILATION & HEATING 2A-9

AIR INLET
DEFLECTOR

SECTION A-A

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Figure 2A-8
2A-10 VENTILATION & HEATING

4. Remove the blower motor housing to heater assemb­

ly duct illustrated in Fig. 2A-9.

Figure 2A-9

NOTE: On air conditioned units, it is necessary to remove

the evaporator to blower motor housing upper and lower
clamps (refer Fig. 2A-10).
 VENTILATION & HEATING 2A-11

2 PLACES
SECTION A-A

SEAL HOLE FROM

ENGINE COMPARTMENT
WITH NON-HARDENING

<l4
SEALER
\

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�
NUT __
2PLACES � \_�� '

\\
8LOWER MOTOR 'iJ..'A... LOWER CLAMP
HOUSING ASM.

�\�.
WASHER_/ �
- �_:..
SCREW

SCREW_}°

Figure 2A-10

( 5. From the base of blower motor housing, remove bolt

securing lower part of housing to left hand dash
panel lower, illustrated in Fig. 2A-9, then disconnect
electrical connector and the vacuum hose from the
vacuum actuator.
6. Remove the nuts securing the blower motor housing
to the studs attached to the left side of the plenum
chamber illustrated in Fig. 2A-9, removing the hou­
sing assembly.

REINSTALL
Reverse removal operations.

2.4 HEATER ASSEMBLY

REMOVE
1. Disconnect battery ground cable.
2. Disconnect vacuum feed hose (TAB No.4) at 'T'
junction on engine side of plenum chamber, adjacent
to windshield wiper motor assembly.
3. Remove the rubber grommet from the dash panel
and the heater hoses from the inlet and outlet heater
core pipes illustrated in Fig. 2A-11, View B.

( I
"--_,__/
2A-12 VENTILATION & HEATING

VIEW�

BEFORE INSTALLATION OF GROMMET,

PUSH VACUUM HOSE (SOURCE TO CHECK
VALVE HOSE) THAU GROMMET UP
TO TAB NO. 4.
FIT GROMMET OVER HEATER PIPES
AND INTO DASH PANEL. ENSURE
PROPER FIT AND SEAL

VIEW (ID

Figure 2A-11

CAUTION: The heater can easily be damaged in the area

of the core tube attachment seams whenever undue
force is exerted on them. This can a/so cause mis­
alignment of the heater door to the heater water valve
assembly, making adjustment extremely difficult. When
the heater hoses do not readily come off the tubes, the
hoses should be cut just forward of the core tubes. The
portion of the hose remaining on the tube should then be
split longitudinally. Once the hoses have been split, they
can be peeled from the tubes without causing damage to
the core.
4. Remove the right side instrument panel lower trim
assembly and left side instrument panel lower (refer
1.1 and 1.4, 'Front End', Section 1 A in this Volume).
5. Remove the heater to blower motor housing assemb­
ly duct, then remove the bolt securing the lower part
of the heater assembly to the floor pan . bracket, as
illustrated in Fig. 2A-1· 2, View A.
NOTE: If air conditioned, · the clamp between the heater
and the evaporator assembly must be loosened to allow
/removal.
6. Remove the heater cable from the snap in clip
located on the side of the heater assembly and
disconnect the inner cable from the lever.
7. Remove the two bolts securing the top of the heater
assembly to the instrument pan·e1 brace as illustrated
in Fig. 2A-12, then remove the heater assembly.
I
REINSTALL \
Reverse removal operations, ensuring that:
1. The heater core pipe grommet effectively seals the
aperture in the lower dash panel (refer Fig. 2A-11,
View 8).
 VENTILATION & HEATING 2A-13

2. Before snapping cable in, lever position must be fully

forward (refer Fig. 2A-12a) with temperature control
lever down.

2 PLACES

HEATER ASSEMBLY

2 PLACES

BLOWER MOTOR
HOUSING ASSEMBLY
( '\

Figure 2A-12

2.5 HEATER CORE AND PIPE

ASSEMBLY

REMOVE
1. Remove heater assembly (refer 2.4).
2. With the right hand side of the heater assembly
uppermost, disconnect door rod adjusting clip 'A',
then remove screw 'B', illustrated in Fig. 2A-13.
3. With the heater assembly in the upright position,
remove the screw attached clamp 'A' illustrated in
Fig. 2A-13 then slide out the core and pipe assembly
from the heater case.
2A-14 VENTILATION & HEATING

REINSTALL
Locate heater control cable lever in closed position and
with heater water valve butterfly closed, connect door rod
adjusting clip 'A' (refer Fig. 2A-13) to rod ensuring the
mechanism operates freely.
Reverse removal procedures. Ensure before snapping
cable in, lever position is fully forward (refer Fig. 2A-12a)
with temperature lever in down position.

FULL FORWARD WITH 11

TEMPERATURE LEVER
IN DOWN POSITION

BEFORE SNAPPING CABLE IN, POSITION MUST BE

FULL FORWARD (AS SHOWN) WITH
TEMPERATURE LEVER IN DOWN POSITION.

Figure 2A-12a

CLAMP RETAINING �

��
SCREW � �
I
HEATER CORE
ASSEMBLY
�

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� HEATER CASE

Figure 2A-13

2.6 WATER VALVE ASSEMBLY -

HEATER CORE

REMOVE
1. From inside the engine compartment, remove the
heater core hoses illustrated in Fig. 2A-11.
 VENTILATION & HEATING 2A-15
CAUTION: The heater can easily be damaged in the area
of the core tube attachment seams whenever undue
force is exerted on them. This can also cause mis­
alignment of the heater door to the heater water valve
assembly making adjustment extremely difficult. When the
(--
, -"",1 heater hoses do not readily come off the tubes, the
hoses should be cut just forward of the core tubes. The
portion of the hose remaining on the tube should then be
split longitudinally. Once the hoses have been split, they
can be peeled from the tubes without causing damage to
the core.
2. Remove the rubber grommet sealing the heater core
pipes passing through the lower dash panel.
3. Using a magnetised cross recess headed screwdriver
located inside of the dash inner panel hole adjacent,
to the heater core outlet pipe, remove the four
screws securing the water valve assembly to the
heater core pipe illustrated in Fig. 2A-13. Disengage
actuating rod from retaining clip then remove the
valve assembly, taking care not to lose the 'O' ring
located between the valve and heater core outlet
pipe.

REINSTALL
Reverse removal procedures. Ensuring heater control is
in 'OFF' position and water valve butterfly is closed.
Connect door rod adjusting clip 'A' (refer Fig. 2A-13) to
rod ensuring the mechanism operates freely.

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