| Removal and Installation NOTE:Four M10 x 120 mm guide bolts are required for removing the dashboard together with the dashboard crossmember. Vehicles with air conditioning | | -
Evacuate the air conditioning (A/C) system.
For additional information, refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
| All vehicles | | -
Drain the cooling system. For additional information, refer to: Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften - 2.0L (303-03 Kühlsystem - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures), Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften - 2.0L (303-03 Kühlsystem - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures). | | | -
Remove the engine cover (2.0L diesel shown). | | | -
Remove the facia crash padding.
For additional information, refer to: Armaturenbrett (501-12, Removal and Installation).
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Remove the A-pillar trim on the right and left-hand sides.
For additional information, refer to: A-Säulenverkleidung (501-05 Innerer Trim und Zierteile, Removal and Installation).
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Remove the front rocker panel trim on the right and left hand sides.
For additional information, refer to: Vordere Einstiegsverkleidung (501-05 Innerer Trim und Zierteile, Removal and Installation).
| 7. Remove the components in the order indicated in the following illustration(s) and table(s). CAUTION:Make sure that the windshield wiper motor is in the park position. 5 - Windshield wiper arm nuts 7 - Clips, cowl panel grille 9 - Bolts for windshield wiper motor with linkage 10 - Windshield wiper motor with linkage (secure to the side) CAUTION:Close off the coolant lines to prevent fluid loss or dirt ingress. CAUTION:Close off the refrigerant lines and the evaporator to prevent dirt ingress. NOTE:Discard the refrigerant line O-rings. 12 - Bolt, refrigerant lines (if equipped) 13 - Refrigerant lines (if equipped) 14 - Steering column bracket upper bolts 16 - Bolt, footwell air duct 18 - Bolt, heater core/evaporator housing 19 - Bolts, bracket for reinforcing element 20 - Bracket, reinforcing element 22 - Connector - passenger compartment wiring harness WARNING:Never perform work on the electric booster heater before the electric booster heater element has cooled to ambient temperature. Failure to observe this instruction can lead to injury. 24 - Bolt, heater core/evaporator housing 25 - Retaining clips, instrument panel wiring harness 27 - Retaining clip, engine compartment wiring harness (if equipped) 28 - Bolts, bracket for reinforcing element 29 - Bracket, reinforcing element 30 - Connector - electric booster heater (if equipped) 31 - Bolt, footwell air duct 33 - Dashboard wiring harness connector 34 - Connector - engine compartment wiring harness 35 - Connector - passenger compartment wiring harness 37 - Heater core upper cover bolts 38 - Heater core upper cover 39 - Dashboard crossmember inner bolts CAUTION:Ensure that no coolant gets into the footwell in order to prevent soiling of the carpet. 43 - Heater housing water drain pipe 8. To install, reverse the removal procedure. NOTE:Install new refrigerant line O-rings. NOTE:Coat the refrigerant line O-rings with clean refrigerant oil before installation. | | -
Check the angle of the windshield wiper arms in relation to the windshield.
For additional information, refer to: Vorderen Wischerarm einstellen (501-16 Scheibenwischer und Scheibenwaschanlage, General Procedures).
| Removal Details Item 2 : Door hinge bolts | | -
Support the door using a trolley jack with the aid of another technician. | Item 3 : Front doors (driver's door shown) | | -
Detach the front door wiring harness connector from the A-pillar. | | | -
Detach the front door wiring harness connector. | Item 4 : Dashboard crossmember side bolts | | -
CAUTION:Do not remove the dashboard crossmember side bolts. Loosen the dashboard crossmember right and left-hand side bolts. | Item 11 : Coolant lines | | -
CAUTION:If brake fluid comes into contact with the paintwork, the affected area must be washed down immediately with cold water. NOTE:Only vehicles with 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) or diesel engine Detach the brake fluid reservoir from the bulkhead extension and tie it back to one side. | | | -
NOTE:Only vehicles with 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) or diesel engine Remove the bulkhead extension. - Pull the bulkhead extension out of the clips.
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CAUTION:Close off the coolant lines to prevent fluid loss or dirt ingress. Detach the coolant lines from the heater core. - Turn the coolant line snap ring counter-clockwise to the stop and detach the coolant line.
| Item 40 : Dashboard crossmember outer bolts | | -
Support the heater housing with a wooden block. | | | -
Detach the air recirculation flap actuator connector. | | | -
Detach the blower resistor connector (if fitted) and the blower motor connector. | | | -
Mark the position of the dashboard crossmember relative to the A-pillars (left-hand side shown). | | | -
After removing the outer bolts of the dashboard crossmember, screw in two M10 x 120 mm guide bolts each into the right and left-hand A-pillars (shown without dashboard crossmember for clarity). | | | -
Remove the right and left-hand side bolts of the dashboard crossmember. | | | -
Pull the dashboard crossmember forwards until it reaches a stop. | Item 41 : Dashboard crossmember | | -
Disconnect the connector from the airbag module. - Unclip the centre console wiring harness and pull it out.
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Detach the steering column shaft joint from the steering column shaft. | | | -
NOTE:Vehicles with EATC only Detach the right-hand temperature flap actuator connector and the defrost flap actuator connector. | | | -
NOTE:Vehicles with EATC only Detach the left-hand temperature flap actuator connector and the air distribution flap actuator connector. | | | -
NOTE:Vehicles with EATC only Detach the air outlet temperature sensor connector. | | | -
Separate the radio antenna cable push-fit connector. | | | -
Separate the car telephone antenna cable push-fit connector (if equipped). | | | -
Detach the overhead console wiring harness connector. | | | -
Remove the right and left-hand M10 x 120 mm guide bolts. | Installation Details Item 40 : Dashboard crossmember outer bolts | | -
Align the dashboard crossmember to the A-pillars (left-hand side shown). | Item 15 : Steering column shaft joint bolt WARNING:Install a new steering column shaft joint bolt. Failure to follow this instruction may result in personal injury. Item 6 : Windshield wiper arms CAUTION:Move the windshield wiper motor to the parked position before installing the wiper arms. Item 2 : Door hinge bolts | | -
Apply thread locking compound to the door hinge bolts. | |
