Fascia Assembly - Vehicles With Single Point Sensed SRS
Fascia Assembly - Vehicles With Single Point Sensed SRS
Service Repair No - 76.46.23/99
WARNING: Refer to SRS safety precautions before commencing repair.
WARNING: The fascia assembly houses the heater distribution unit, blower assemblies and air conditioning evaporator. Assistance is essential during removal and refit procedures.
CAUTION: When removed from the vehicle, the fascia should be placed on a soft covered work surface, supported on suitable wooden blocks.
Remove
1. Remove key from starter switch and wait 10 minutes for SRS back up power circuit to discharge.
2. Disconnect both battery terminals, earth lead first.
3. Drain cooling system.
4. Release 2 clips securing heater hoses to heater matrix and disconnect hoses.
5. Cap both heater matrix pipes 10 prevent coolant spillage inside vehicle during fascia removal.
6. Recover refrigerant from air conditioning system.
7. Remove bolt securing pipe clamp to thermostatic expansion valve (TXV) and release pipes.
8. Remove and discard '0' ring seals from air conditioning pipes.
9. Immediately cap both air conditioning pipes and TXV ports to prevent moisture entering the air conditioning system.
10. Remove wiper motor and linkage.
11. Disconnect passenger side heated screen multiplug.
12. Release heated screen multiplug from scuttle side panel and position aside.
13. Remove 6 bolts securing scuttle side panel to scuttle and remove panel.
14. Remove pollen filter from both heater intake housings.
15. Remove 8 screws securing each heater intake housing to scuttle and remove intake housings. Release sealing rubbers from scuttle panel aperture.
16. Remove center console.
17. Remove transmission tunnel insulation pad.
18. Release latching mechanism and disconnect multiplug from airbag diagnostic and control unit (DCU).
19. Release SRS harness from transmission tunnel and position to fascia to avoid snagging.
20. Remove 6 nuts securing gear lever gaiter ring to transmission tunnel and release gaiter.
21. Remove 2 bolts securing gear lever to gearbox remote and remove gear lever.
22. Disconnect high/low switch multiplug.
23. Remove 4 bolts securing fascia center bracket to fascia and transmission tunnel.
24. Remove fascia center bracket.
25. Remove radio.
26. Remove steering column.
27. Remove 3 scrivets securing lower fascia closing panel to passenger's side of fascia.
28. Release closing panel and release diagnostic connector from panel.
29. Release door aperture seal adjacent to 'A' post lower trim panels.
30. Remove screw securing each 'A' post lower trim panel to 'A' post.
31. Release 'A' post lower trim panels from sprag clip and remove panels.
32. Remove fuse box cover from driver's seat base trim.
33. Remove screw and 3 trim studs securing seat base trim to body and remove seat base trim.
34. Release 4 sprag clips securing driver's side carpet retainer to body and remove carpet retainer.
35. Disconnect 3 multiplugs from Body Electrical Control Module (BeCM).
36. Position carpet aside and disconnect multiplug from rear of BeCM.
37. Remove captive nut securing earth wires to driver's side lower 'A' post and release 3 additional earth wires.
38. Disconnect 3 multiplugs at base of driver's side 'A' post.
39. Release harness from driver's side carpet and position to fascia to avoid snagging.
40. Disconnect multiplugs from clutch and 2 brake pedal switches.
41. Disconnect vacuum hose from clutch and brake pedal switches.
42. Disconnect 2 multiplugs at base of passenger's side 'A' post.
43. Remove 2 nuts securing fascia to 'A' post and transmission tunnel bracket, passenger's side
44. Remove 2 nuts securing fascia to 'A' post and transmission tunnel bracket, driver's side.
45. Remove 4 tube bolts securing fascia assembly to scuttle panel.
46. Disconnect 2 evaporator drain hoses from evaporator.
47. Using assistance, carefully maneuver fascia assembly through the driver's door aperture. Position the fascia on a work surface with a soft covering and support on suitable wooden blocks.
48. Collect 2 ducts connecting rear heating pipes to fascia assembly.
Refit
49. Tape intake duct seals inside blower duct to aid fitment.
50. Fit guide pins LRT-76-OO1 to outer fascia studs.
51. With assistance, maneuver fascia assembly through driver's door aperture and locate guide pins to scuttle panel.
NOTE: Assistance from a third person may be required to guide heater pipes through bulkhead.
52. Fit one tube bolt securing fascia to scuttle panel but do not tighten.
53. Fit nuts securing fascia to lower 'A' posts.
^ Tighten to 25 Nm (18 ft.lbs)
54. Fit nuts securing fascia to transmission tunnel brackets.
^ Tighten to 25 Nm (18 ft.lbs)
55. Remove LRT-76-OO1.
56. Fit remaining tube bolts securing fascia to scuttle panel.
^ Tighten to 25 Nm (18 ft.lbs)
57. Fit fascia center bracket, fit bolts.
^ Tighten to 25 Nm (18 ft.lbs)
58. Connect evaporator drain hoses to evaporator.
59. Fit ducts connecting rear heating pipes to fascia assembly.
60. Fit gear lever to gearbox remote, fit bolts.
^ Tighten to 25 Nm (18 ft.lbs)
61. Fit gear lever gaiter and ring to transmission tunnel and secure with nuts.
62. Connect high/low switch multiplug.
63. Position SRS harness to transmission tunnel.
64. Connect multiplug to airbag DCU. Ensure connector latching mechanism is correctly engaged.
65. Fit transmission tunnel insulation pad to transmission tunnel and position multiplugs through pad.
66. Fit radio.
67. Connect multiplugs at base of passenger's side 'A' post.
68. Fit passenger's side 'A' post lower trim panel and secure with screw.
69. Engage door aperture seal to door aperture.
70. Position fascia lower closing panel and engage diagnostic connector to panel.
71. Position closing panel to fascia and secure with scrivets.
72. Connect vacuum hose to clutch and brake pedal switches.
73. Connect multiplugs to clutch and brake pedal switches.
74. Position harness to driver's side carpet.
75. Connect multiplugs to BeCM.
76. Connect multiplugs at base to driver's side 'A' post.
77. Position earth wires to 'A' post stud, fit and secure captive nut.
78. Fit driver's side carpet retainer and engage to clips.
79. Fit seat base trim and secure with trim studs and screw.
80. Fit seat base fuse box cover.
81. Fit driver's side lower 'A' post trim and secure with screw.
82. Fit steering column.
83. Fit radio.
84. Fit center console.
85. Remove tape from heater intake ducts.
86. Engage heater intake seals to scuttle apertures.
87. Fit heater intake housings and secure with screws.
88. Fit pollen filters to intake housings.
89. Fit wiper motor and linkage.
90. Fit scuttle side panel to scuttle and secure with bolts.
91. Connect heated screen multiplug and engage multiplug to scuttle side panel bracket.
92. Remove caps from heater matrix pipes.
93. Engage heater matrix grommet to bulkhead aperture.
94. Connect heater hoses to heater matrix and secure with clips.
95. Remove caps from air conditioning pipes and TXV.
96. Lubricate NEW '0' ring seals with clean compressor oil and fit to air conditioning pipes.
97. Connect air conditioning pipes to TXV, position clamp and fit bolt.
98. Tighten clamp bolt to 6 Nm (4 ft.lbs)
99. Charge air conditioning system.
100. Fill coolant system.
101. Connect both battery terminals, earth lead last.