In-Vehicle Crossbeam

In-Vehicle Crossbeam

Removal

WARNING:
^ Persons working on the supplemental restraint system (SRS) must be fully trained and have been issued with the safety guidelines.
^ Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the SRS.
^ The SRS electrical connectors are unique. DO NOT force, or attempt to connect electrical connectors to the wrong sockets.
^ The correct procedures must always be used when working on SRS components.
^ It is imperative that before any work is undertaken on the SRS system, the appropriate information is read thoroughly.
^ Always disconnect both battery cables before beginning work on the SRS system. Disconnect the ground cable first. Never reverse connect the battery.
^ Take extra care when handling SRS components.

1. Make the air bag supplemental restraint system (SRS) safe.
2. Disconnect the battery ground cable.
3. Remove the plenum chamber.
4. Recover the air conditioning (A/C) refrigerant.
5. Remove the instrument panel reinforcement.
6. Release the battery positive cable.
^ Remove the nut.







7. Remove the plenum chamber support.
^ Remove the 3 bolts.
^ Remove the 2 nuts.







8. Using 3 suitable pipe clamps, clamp the 3 heater core coolant hoses.







9. CAUTION: Make sure that all openings are sealed. Use new blanking caps.

Disconnect the 3 heater core coolant hoses.
^ Position a container to collect the fluid spillage.
^ Release the 3 clips.
^ Install blanking caps to the exposed ports.

10. Remove the grommet.







11. CAUTION: Make sure that all openings are sealed. Use new blanking caps.

Disconnect the 2 A/C refrigerant lines.
^ Remove the 2 bolts.
^ Remove and discard the 2 O-ring seals.
^ Install blanking caps to the exposed ports.
^ Remove the grommet.







12. Release the heater and evaporator core housing from the bulkhead.
^ Remove the 3 nuts.







13. Reposition the windshield wiper motor for access.
^ Mark the position of the wiper linkage to aid assembly.
^ Remove the windshield wiper motor to wiper linkage assembly nut.
^ Remove the windshield wiper motor to support bracket bolts.







14. Release the in-vehicle crossbeam from the bulkhead.
^ Remove the 2 bolts.







15. Remove the steering column.
16. Release the wiring harness from the driver side of the in-vehicle crossbeam.
^ RH drive vehicles only: Remove and discard the tie-strap.
^ Release the 3 wiring harness clips.







17. Release the wiring harness from the center of the in-vehicle crossbeam.
^ Release the wiring harness fir tree clip.
^ Release the 2 wiring harness clips.
^ Remove and discard the tie-strap.







18. Disconnect the main wiring harness to the A/C wiring harness.
^ Disconnect the 2 electrical connectors.







19. Disconnect the audio wiring harness to the main wiring harness.
^ Disconnect the 2 electrical connectors.
^ Release the 2 electrical connectors from the in-vehicle crossbeam.







20. Disconnect the passive anti-theft system (PATS) electrical connector.







21. NOTE: LHD illustration shown, RHD is similar.

Release the gearshift interlock cable from the in-vehicle crossbeam.
^ Remove and discard the tie-strap.







22. Release the wiring harness clip from the passenger side of the in-vehicle crossbeam.







23. Disconnect the rear blower motor electrical connector.
^ Release the electrical connector from the clip.

24. Release the wiring harness from the passenger side of the in-vehicle crossbeam.
^ Release the 8 clips.







25. Release the wiring harness from the passenger side of the in-vehicle crossbeam.
^ Remove and discard the tie-strap.







26. Remove the passenger side footwell duct.
^ Remove the screw.







27. Release the battery positive cables.
^ Remove and discard the tie-strap.







28. NOTE: LHD illustration shown, RHD is similar.

Disconnect the 4 electrical connectors from the air suspension control module.
^ Release the wiring harness clip.







29. Remove the audio unit 4 screws and wiring harness clip.







30. Disconnect the 4 electrical connectors and remove the audio unit.







31. NOTE: LHD illustration shown, RHD is similar.

Release the central junction box (CJB) from the in-vehicle crossbeam.
^ Release the 2 relays from the passenger side of the in-vehicle crossbeam.
^ Release the wiring harness clip.
^ Remove the 4 screws.
^ Reposition the CJB assembly for access.







32. NOTE: LHD illustration shown, RHD is similar.

Release the wiring harness carrier from the in-vehicle crossbeam.
^ Remove and discard the tie-strap.

33. Remove the 2 nuts from the heater and evaporator core housing to the in-vehicle crossbeam.







34. Release the in-vehicle crossbeam from the bulkhead.
^ Remove the 4 nuts.
^ Remove the 2 bolts.

35. Reposition the in-vehicle crossbeam for access.







36. Remove the 3 nuts securing the wiring harness carrier to the in-vehicle crossbeam.
^ Release the wiring harness carrier from the in-vehicle crossbeam.

37. Remove the heater and evaporator core housing to floor ducts.
^ Position the heater and evaporator core housing assembly in an upwards direction.







38. With assistance, remove the in-vehicle crossbeam.
^ Release the wiring harness rearwards for in-vehicle crossbeam removal access.

Installation

1. With assistance, install the in-vehicle crossbeam.
2. Install the heater and evaporator core housing to floor ducts.
3. Locate the wiring harness carrier to the in-vehicle crossbeam and install the nuts.
4. Install the in-vehicle crossbeam to the bulkhead.
^ Tighten the nuts to 25 Nm (18 ft. lbs.).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).

5. Secure the heater and evaporator core housing to the in-vehicle crossbeam.
6. Secure the wiring harness to the in-vehicle crossbeam.
^ Secure with a tie-strap.

7. Install the CJB.
^ Secure the wiring harness clip.
^ Install the screws.
^ Install the 2 relays to the passenger side of the in-vehicle crossbeam.

8. Install the audio unit.
^ Connect the electrical connectors.

9. Secure the audio unit.
^ Install the screws.
^ Secure the wiring harness clip.

10. Connect the electrical connectors to the air suspension control module.
^ Secure the wiring harness clip.

11. Secure the battery positive cables.
^ Secure with a tie-strap.

12. Install the passenger side footwell duct.
^ Install the screw.

13. Secure the wiring harness to the passenger side of the in-vehicle crossbeam.
^ Secure the wiring harness clips.

14. Secure the wiring harness.
^ Secure with a tie-strap.

15. Secure the wiring harness clips to the passenger side of the in-vehicle crossbeam.
16. Connect and secure the rear blower motor electrical connector.
17. Secure the wiring harness to the passenger side of the in-vehicle crossbeam.
18. Secure the gearshift interlock cable to the in-vehicle cross beam.
^ Secure with a tie-strap.

19. Connect the PATS module electrical connector.
20. Connect the audio wiring harness to the main wiring harness.
^ Connect the electrical connectors.
^ Secure the electrical connectors to the in-vehicle crossbeam.

21. Connect the main wiring harness to the A/C wiring harness.
^ Connect the electrical connectors.

22. Secure the wiring harness to the center of the in-vehicle crossbeam.
^ Secure the wiring harness clips.
^ Secure the wiring harness clip.
^ Secure with a tie-strap.

23. Secure the wiring harness to the driver side of the in-vehicle crossbeam.
^ Secure the wiring harness clips.

24. Install the in-vehicle crossbeam to bulkhead bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).

25. Install the steering column.
26. Install the windshield wiper motor.
^ Reposition the windshield wiper motor.
^ Install the bolts.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
^ Reposition the wiper linkage to its original position.
^ Install the windshield wiper motor to wiper linkage assembly nut.
^ Tighten the nut to 25 Nm (18 ft. lbs.).

27. Install the heater and evaporator core housing to bulkhead.
^ Tighten the nuts to 10 Nm (7 ft. lbs.).

28. Connect the A/C refrigerant lines.
^ Install the grommet.
^ Remove the blanking plugs.
^ Clean the component mating faces.
^ Lubricate and install the new O-rings.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).

29. Connect the coolant hoses to the heater core pipes.
^ Remove the blanking plugs.
^ Install the rubber grommet.
^ Connect the coolant hoses and secure with the clips.
^ Remove the container.
^ Remove the coolant hose clamps.

30. Install the plenum chamber support.
^ Tighten the bolts and nuts to 10 Nm (7 ft. lbs.).

31. Connect the battery positive cable.
^ Tighten to 20 Nm (15 ft. lbs.).

32. Install the instrument panel reinforcement.
33. Recharge the A/C system.
34. Install the plenum chamber.
35. Connect the battery ground cable.