For 1990-2009 cars

## Radiator Air Lower Baffle and Deflector Replacement HSV Maloo

### Removal Procedure - Type B

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Important: The Type B air baffle is a combination of two parts, a revised Type A air baffle and a Type B air baffle.

Important: Steps 3 through 8 are not required when Type B air baffle is being replaced. Steps 3 through 8 are only applicable when Type A and Type B are being replaced.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the air deflector. Refer to Front Air Deflector Replacement .
3. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
4. Remove the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement .
5. Remove the washer solvent container. Refer to Windshield Washer Solvent Container Replacement .
6. Detach the ambient air temperature sensor and ambient air temperature sensor wiring loom. Refer to Ambient Air Temperature Sensor Replacement .
7. Remove the retaining pins (1) located at either side of the lower air baffle (2).
8. Remove the lower air baffle (2) from the front of vehicle.
9. Drill out the 6 rivets (3) and separate the Type B air baffle (1) from the Type A air baffle (2) .
10. Inspect all parts for wear and damage. Replace as necessary.

### Installation Procedure - Type B

Caution: Refer to Safety Glasses Caution in the Preface section.

Important: For complete air baffle replacement, Type A and Type B air baffles are required.

1. Using a suitable tool, remove the indicated material (1) from the Type A lower air baffle (2). Indicated material for removal is to be cut from forward edge of the third strengthening rib (3) from the front.
2. Align the Type B air baffle (1) against the revised Type A lower air baffle (2).
3. Drill 6 x 4.5 mm diameter holes (3) through the modified Type A lower air baffle (2), using the Type B air baffle (1) as a template.
4. Rivet the Type A lower air baffle (2) and Type B lower air baffle (1) together using 4.1 mm diameter "spreader type" rivets in the six places (3).
5. Install the retaining pins (1) located at either side of the lower air baffle (2).
6. Attach the ambient air temperature sensor and ambient air temperature sensor wiring loom. Refer to Ambient Air Temperature Sensor Replacement .
7. Install the washer solvent container. Refer to Windshield Washer Solvent Container Replacement .
8. Install the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement .
9. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
10. Install the air deflector. Refer to Front Air Deflector Replacement .
11. Lower the vehicle.
12. Inspect the vehicle for correct alignment of body panels. Refer to Dimensions - Body .

## Radiator Air Lower Baffle and Deflector Replacement Except HSV Maloo

### Removal procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

1. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the air deflector. Refer to Front Air Deflector Replacement .
3. Remove the front fascia. Refer to Front Bumper Fascia Replacement .
4. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement .
5. Lower the vehicle.
6. Detach the ambient sensor. Refer to Ambient Air Temperature Sensor Replacement .
7. Remove the washer solvent container. Refer to Windshield Washer Solvent Container Replacement .
8. Detach the wiring loom from the duct.

Caution: Refer to Safety Glasses Caution in the Preface section.

9. Remove the retaining pins (1) on either side of the air baffle (2).
10. Remove air baffle out of locating lugs and remove from front of vehicle.

### Installation Procedure

1. Install the air baffle into the locating lugs.
2. Install the air baffle retaining pins (1) located at either side of the baffle (2).
3. Attach the wiring loom to the duct.
4. Attach the ambient sensor. Refer to Ambient Air Temperature Sensor Replacement .
5. Install the washer solvent container. Refer to Windshield Washer Solvent Container Replacement .

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

6. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle .
7. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement .
8. Install the front fascia. Refer to Front Bumper Fascia Replacement .
9. Instal the air deflector. Refer to Front Air Deflector Replacement .
10. Lower vehicle.
11. Inspect vehicle for correct alignment of body panels. Refer to Dimensions - Body .