In-Vehicle Crossbeam

In-Vehicle Crossbeam

Removal

1. Rotate the steering wheel until the front wheels are in the straight-ahead position.

2. Drain the coolant.

3. Recover the refrigerant.

4. Remove the wiper mounting arm and pivot shaft assembly.

5. Disconnect the 3 PCM electrical connectors.

6. Remove the wire harness retainer from the PCM bracket stud.





7. Remove the 2 nuts and the PCM.





8. Remove the 3 nuts and the PCM bracket.





9. Remove the vacuum hose clip from the strut tower cross brace.





10. NOTE: LH side shown, RH side similar.

Remove the strut tower cross brace.

- Remove the LH and RH strut upper mount inboard nuts.






11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and position aside.





12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.





13. Loosen the ACL (Air Cleaner) outlet pipe-to-Throttle Body (TB) clamp and the ACL (Air Cleaner) outlet pipe-to-ACL (Air Cleaner) cover clamp.





14. Remove the ACL (Air Cleaner) outlet pipe.

15. Remove the heater hoses from the heater hose separator.





16. Remove the heater hoses from the heater hose tubes and position aside.





17. Remove the heater hoses from the heater core and position aside.





18. Remove the Thermostatic Expansion Valve (TXV) manifold fastener and the TXV (Thermostatic Expansion Valve) manifold.
- Discard the O-ring seals.






19. Remove the RH and LH instrument panel upper cowl bolts.

20. Remove the front seats.

21. Remove the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section Instrument Panel Upper Section.

22. Disconnect the LH instrument panel bulkhead electrical connector.





23. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical connector.





24. Remove and discard the steering column shaft-to-steering column bolt.





25. Detach the steering column shaft from the steering column.

26. Remove the driver footrest pad.
- Remove the 2 pin-type retainers.






27. NOTICE: To avoid damaging the carpet with coolant when the instrument panel is removed, the carpet must be removed.

Remove the LH and RH front carpet sections.
- Remove the 2 pin-type retainers.


28. If equipped, remove the 2 pin-type retainers and the rear footwell duct.





29. Disconnect the RH bulkhead electrical connector, antenna cable and if equipped, the satellite radio antenna connector.





30. Remove the 2 bolts and the ground wires.





31. Disconnect the Restraints Control Module (RCM) small electrical connector and detach the 2 wire harness pin-type retainers.





32. Remove the 4 instrument panel center support bracket bolts.

33. NOTE: An assistant is required when carrying out this step.

NOTE: Remove the bolts from one side of the in-vehicle cross beam and support the in-vehicle cross beam before removing the bolts from the opposite side.

Remove the 3 LH and 3 RH instrument panel side bolts.


34. NOTICE: To avoid damaging the RH front door trim panel when removing the in-vehicle cross beam from the vehicle, an assistant is required when carrying out this step.

NOTICE: Make sure that all electrical connectors and wiring are not hindered before removing the in-vehicle cross beam or damage to the components may occur.

Remove the in-vehicle cross beam from the vehicle.


Installation

1. NOTICE: To avoid damaging the RH door trim panel when installing the in-vehicle cross beam into the vehicle, an assistant is required when carrying out this step.

NOTICE: Make sure that all electrical connectors and wiring are correctly routed when installing the in-vehicle cross beam or damage to the components may occur.

Install the in-vehicle cross beam into the vehicle.


2. Install, but do not tighten, the 6 instrument panel side bolts.

3. Install, but do not tighten, the 4 instrument panel center support bolts.

4. Install, but do not tighten, the 3 instrument panel upper cowl bolts.

5. Tighten the 6 instrument panel side bolts.
- Tighten to 40 Nm (30 lb-ft).


6. Tighten the 4 instrument panel center support bracket bolts.
- Tighten to 25 Nm (18 lb-ft).


7. Tighten the 3 instrument panel upper cowl bolts.
- Tighten to 25 Nm (18 lb-ft).


8. Connect the small RCM (Restraints Control Module) electrical connector and attach the wire harness pin-type retainers.





9. Install the ground wires and the 2 bolts to the floor pan tunnel.
- Tighten to 10 Nm (89 lb-in).






10. Connect the RH bulkhead electrical connector, antenna cable and if equipped, the satellite radio connector.





11. If equipped, install the rear footwell duct and the 2 pin-type retainers.





12. Install the LH and RH front carpet sections.
- Install the 2 pin-type retainers.


13. Install the driver footrest pad.
- Install the 2 pin-type retainers.






14. Install the steering column shaft to the steering column.

15. Install a new steering column shaft-to-steering column bolt.
- Tighten to 25 Nm (18 lb-ft).






16. Connect the 2 SJB (Smart Junction Box) electrical connectors and the lower bulkhead electrical connector.





17. Connect the LH bulkhead electrical connector.





18. Install the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section Instrument Panel Upper Section.

19. Install the PCM bracket.
- Install and tighten the 3 PCM bracket nuts.






20. Install the PCM.
- Install and tighten the 2 PCM nuts.
- Tighten to 5 Nm (44 lb-in).






21. Install the wire harness retainer onto the PCM bracket stud.





22. Connect the 3 PCM electrical connectors.

23. Install the front seats.

24. Install the TXV (Thermostatic Expansion Valve) manifold in the following sequence.
1. Install new O-ring seals.

2. Install and tighten the TXV (Thermostatic Expansion Valve) manifold fastener.
- Tighten to 8 Nm (71 lb-in).






25. Install the heater hoses onto the heater core.





26. Install the heater hoses onto the heater hose tubes.





27. Install the heater hose separator.





28. Install the ACL (Air Cleaner) outlet pipe.
- Tighten the ACL (Air Cleaner) outlet pipe-to-TB (Throttle Body) clamp and the ACL (Air Cleaner) outlet pipe-to-ACL (Air Cleaner) cover clamp.






29. Install the crankcase vent tube and the vacuum tube onto the ACL (Air Cleaner) outlet pipe.





30. Connect the vacuum hose and the evaporator purge solenoid hose to the upper intake manifold.





31. Install the strut tower cross brace.
- NOTE: LH side shown, RH side similar.
Install the LH and RH strut upper mount nuts.

- Tighten to 30 Nm (22 lb-ft).






32. Install the vacuum hose clip onto the strut tower cross brace.





33. Install the wiper mounting arm and pivot shaft assembly.

34. Charge the refrigerant.

35. Fill the cooling system.