Cowl: Service and Repair

Secondary Bulkhead Center Panel

Removal

All vehicles
1. Remove the cowl vent screen.
2. Carry out the air conditioning (A/C) system recovery procedure.

Right-hand drive vehicles
3. Drain the cooling system.
4. Remove the air deflector.
5. Detach the transmission harness electrical connectors from the retaining bracket.







6. Disconnect the transmission harness electrical connectors.







7. Lower the vehicle.
8. Detach the brake booster vacuum pipe from the vacuum pump.







9. Detach the differential pressure sensor retaining bracket.
- Remove the retaining nut.







10. Remove the engine compartment support brace.
- Remove the retaining bolts.







Left-hand drive vehicles
11. Detach and reposition the brake booster vacuum pipe.







12. NOTE: Fit suitable blanking caps to the fuel filter unions, fuel supply lines and fuel return lines.

Detach the fuel filter supply and return lines.







13. Loosen the fuel filter retaining bolt.







14. Remove the fuel filter from the retaining bracket.







15. Remove the fuel filter retaining bracket.
- Remove the retaining bolts.







16. Remove the engine compartment support brace.
- Remove the retaining bolts.







17. Remove the secondary bulkhead center panel left-hand retaining scrivet.







18. Remove the secondary bulkhead center panel right-hand retaining scrivet.







Right-hand drive vehicles
19. Remove the secondary bulkhead center panel right-hand retaining scrivet.







20. Remove the secondary bulkhead center panel left-hand retaining scrivet.







21. Detach the heater hoses.
- Reposition the heater hose retaining clips.







Left-hand drive vehicles

22. NOTE: Cap the heater hoses to prevent coolant loss.

Detach the heater hoses.
- Reposition the heater hose retaining clips.







23. Detach the transmission harness electrical connectors from the retaining bracket.







24. Disconnect the transmission harness electrical connectors.







All vehicles

25. NOTE: Right-hand drive vehicle shown, left-hand drive vehicle similar.

Remove the secondary bulkhead center panel retaining bracket.
- Remove the retaining bolts.
- Remove the retaining scrivets.







26. NOTE: Remove and discard the O-ring seals.

NOTE: Cap the air conditioning ports.

Detach the evaporator core supply and return pipes.
- Remove the retaining nut.







27. Remove the engine harness cover.







28. Remove the engine harness casing.
- Remove the retaining bolts.







29. NOTE: Right-hand drive vehicle shown, left-hand drive vehicle similar.

Loosen the engine harness retaining nut.







Right-hand drive vehicles
30. Remove the injector sound proofing.







31. Disconnect the port de-activation vacuum hose.







All vehicles

32. NOTE: Right-hand drive vehicle shown, left-hand drive vehicle similar.

Detach the engine harness.







33. NOTE: Right-hand drive vehicle shown, left-hand drive vehicle similar.

Detach and reposition the engine harness towards the front of the vehicle.







Right-hand drive vehicles
34. Detach and reposition the secondary bulkhead center panel.







35. Remove the secondary bulkhead center panel.







Left-hand drive vehicles
36. Detach the brake line grommet.







37. Detach and reposition the secondary bulkhead center panel.







38. Detach the bonnet release cable from the secondary bulkhead center panel.







39. Remove the secondary bulkhead center panel.







Installation

All vehicles
1. To install, reverse the removal procedure.
- Tighten to 7 Nm.







2. Tighten to 4 Nm.







3. Tighten to 8 Nm.
- Fit new O-ring seals.







4. Tighten to 25 Nm.







Left-hand drive vehicles
5. Tighten to 25 Nm.







6. Tighten 10 mm (0.394 inch's) bolt to 25 Nm.
- Tighten 6 mm (0.236 inch's) bolt to 8 Nm.







7. Tighten to 7 Nm.







Right-hand drive vehicles
8. Tighten to 25 Nm.







9. Tighten to 25 Nm.







All vehicles
10. Carry out coolant system filling and bleeding procedure.
11. Carry out the air conditioning system evacuation and charging procedure.