Fascia - Remove For Access & Refit

Fascia - Remove For Access & Refit

Service Repair No - 76.46.23.99

This procedure shows how to position the fascia aside for access. The fascia is released from the passenger side and swung aside for access, with the main harness still attached to the fascia.

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

Remove

1. Make the SRS system safe.
2. Drain coolant.
3. Recover refrigerant from A/C system.
4. Remove air intake plenum.
5. Remove front seats.
6. Remove heater control panel.
7. Remove air suspension control panel.
8. Remove handbrake lever assembly.
9. Remove footwell closing panels.
10. Release and remove air ducts from HEVAC assembly.
11. LHD only: Remove drivers footrest.
12. Remove 'A' post lower finisher.
13. Remove 'A' post upper finishers.
14. Remove drivers side fascia finisher.
15. Remove passenger side fascia finisher.
16. Remove gearshift selector assembly.





17. Remove 4 nuts securing selector carrier to body and remove.
18. Cover studs to prevent damage to fascia on removal.





19. Remove 4 bolts securing handbrake mounting bracket to body and remove bracket.





20. Remove 4 bolts securing center console support bracket to body and remove bracket.





21. Noting fitted position remove Torx bolt from clamp securing steering column lower shaft to intermediate shaft.
22. Remove 2 nuts securing steering support bearing to body release bearing and disconnect shaft.





23. Noting fitted position, remove nut and disconnect arm from wiper motor.
24. Remove 3 bolts securing wiper motor to mounting bracket collect motor and move aside for access.





25. Remove 2 bolts securing fascia to bulkhead.





26. Remove 2 Allen bolts securing A/C pipes to bulkhead, disconnect pipes and discard 'O' rings.

CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.

27. Position container to collect coolant.
28. Release clips and disconnect coolant hoses from heater matrix at bulkhead.
29. Remove 3 nuts securing heater assembly to bulkhead.





30. Remove 4 nuts and 2 bolts securing fascia assembly to body.
31. Cover fascia lower brackets to protect carpet from damage.





32. Disconnect 2 multiplugs and release harness clip from 'A' post, adjacent to top rail. Repeat on opposite side. Tape disconnected leads to windscreen.
33. Withdraw fascia sufficiently to disconnect 'A' post airbag multi-plugs.
34. Passenger side only: Release 2 additional 'A' post harness clips.
35. Remove transfer box ECU.





36. Disconnect positive feed from bulkhead fuse box.
37. Disconnect relay and multiplug from bulkhead fuse box.
38. Release harness from bulkhead and position aside.





39. Disconnect 2 multiplugs from fuel burning heater, if fitted.
40. Disconnect harness from side repeater lamp, release harness grommet from inner wing and withdraw harness.
41. Remove front passenger side wheelarch liner.





42. Release harness from clips on inner wing.
43. Remove 10 Allen screws securing 'E' box cover and remove cover.





44. Remove 2 bolts securing 'E' box to suspension turret, move aside for access.





45. Release air intake duct from inner wing and remove.





46. Remove nuts and disconnect harness earth headers.
47. Remove front bumper.





48. Disconnect hose from rear washer pump.





49. Release 4 cable ties securing washer hose to armature and move hose aside.
50. Disconnect horn multiplugs.
51. Remove indicator lamp.





52. Disconnect headlamp multiplug.





53. Note fitted position of ride height sensor cable ties, remove cable ties and disconnect multiplug.





54. Disconnect multiplugs from radiator pack.





55. Disconnect multiplug from ABS sensor.





56. Disconnect multiplug from A/C switch.





57. Disconnect multiplug from A/C compressor.





58. Remove screw securing light check control module to 'A' post.
59. Move light check module aside.





60. Remove bolt securing door harness connector block to 'A' post and disconnect multiplug.





61. Remove nut securing earth header to 'A' post and release header.





62. Raise carpet and remove 3 scrivets securing harness closing panel to body release and remove panel.





63. Release clips securing harness connector block to BCU carrier.





64. Remove 2 nuts and move BCU carrier aside.
65. Release main harness from channel and reposition carpet.
66. With assistance withdraw harness through bulkhead and rotate fascia assembly for access.

CAUTION: Ensure evaporator drain tubes are not damaged when moving fascia.

67. Support fascia on suitably protected axle stands, avoiding damage to carpet and trim.

Refit
1. With assistance position harness and fascia assembly to bulkhead.
2. Connect airbag and 'A' post multiplugs.
3. Raise carpet, position main harness, fit and secure closing panel with scrivets.
4. Fit carpet.
5. Fit and secure BCU carrier.
6. Fit and secure 'A' post earth header.
7. Connect door harness multiplug and secure with bolt.
8. Fit and secure light check module.
9. Position harness, connect multiplugs to radiator pack, A/C pressure switch, A/C compressor, ABS and ride height sensor.
10. Connect multiplug to height sensor
Ensure the ride height sensor harness and cable ties are correctly fitted.
11. Connect horn and headlamp multiplugs.
12. Fit side and flasher lamp assembly.
13. Connect rear screen washer tube.
14. Fit rear screen washer hose to armature and secure with cable ties.
15. Fit front bumper.
16. Fit 'E' box to mounting bracket and tighten bolts to 3 Nm (2.2 ft. lbs.).
17. Fit 'E' box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs.).
18. Secure harness to inner wing.
19. Fit and secure wheelarch liner.
20. Position harness, fit and secure side repeater lamp.
21. Position harness, fit and secure FBH multiplugs.
22. Connect relay to bulkhead fuse box mounting.
23. Connect positive feed to bulkhead fuse box.
24. Fit transfer box ECU.
25. Secure fascia to bulkhead, fit nuts and bolts tighten to 25 Nm (18 ft. lbs.).
26. Secure 'A' post harness with clips.
27. Fit nuts securing HEVAC to bulkhead tighten to 10 Nm (7 ft. lbs.).
28. Fit coolant hoses and secure with clips.
29. Lubricate new 'O' rings with clean refrigerant oil and fit to pipe/hose assembly.
30. Connect A/C pipes to bulkhead fit bolts and tighten to 25 Nm (18 ft. lbs.).
31. Fit bolts securing fascia to bulkhead and tighten to 25 Nm (18 ft. lbs.).
32. Position wiper motor to bracket, fit bolts and tighten to 10 Nm (7 ft. lbs.).
33. Position wiper linkage to motor, fit nut and tighten to 25 Nm (18 ft. lbs..)
34. Connect steering column assembly, fit nuts to support bearing and tighten to 25 Nm (18 ft. lbs.).
35. Fit Torx bolt to steering clamp and tighten to 25 Nm (18 ft. lbs.).
36. Fit center console support bracket and tighten bolts to 10 Nm (7 ft. lbs.).
37. Fit handbrake mounting bracket to body, fit bolts and tighten to 25 Nm (18 ft. lbs.).
38. Fit selector carrier and tighten nuts to 25 Nm (18 ft. lbs.).
39. Fit gearshift selector assembly.
40. Fit passenger side upper finisher.
41. Fit drivers side upper trim finisher.
42. Fit `A' post upper finishers.
43. Fit lower 'A' post finisher.
44. Fit drivers footrest.
45. Fit and secure ducts to heater assembly.
46. Fit center console closing panel
47. Fit handbrake lever assembly.
48. Fit air suspension switch panel.
49. Fit heater control panel.
50. Fit front seats.
51. Fit air intake plenum.
52. Recharge A/C system.
53. Refill cooling system.
54. Connect battery earth lead.