516819 Removing and Installing Dashboard Support
WM 516819 Removing and installing dashboard support
Technical values
Preliminary work
1. Remove dashboard. -> 701819 Removing and installing dashboard - section on "Removing" 701819 Removing and installing instrument panel
2. Remove air guides. -> 853419 Removing and installing air guide - section on "Removing" 85341900 Removing and installing air guide
3. Remove tunnel support. -> 684419 Tunnel support - section on "Removing" 68441900 Removing and installing tunnel support
4. Remove relay carrier 1. -> 978319 Removing and installing relay carrier 1 - section on "Removing" 97831900 Removing and installing relay carrier 1
5. Remove vehicle electrical system control unit with bracket. -> 971019 Removing and installing vehicle electrical system control unit - section on "Removing" Service and Repair
6. Remove control unit for KESSY/PAS. -> 966619 Removing and installing KESSY/PAS control unit - section on "Removing" Service and Repair
Information
Only for vehicles with manual transmission.
7. Remove clutch pedal -> 300519 Removing and installing clutch pedal - section on "Removing" Service and Repair
8. Remove brake light switch. -> 943619 Removing and installing brake light switch - section on "Removing" Service and Repair
9. Remove brake pedal. -> 460519 Removing and installing brake pedal - section on "Removing" Service and Repair
Information
To prevent damage to the steering column, support the steering column with a suitable object or tie it to the side using tie-wraps.
10. Release steering column, disconnect steering column plug connection and let it hang down. -> 481519 Removing and installing steering column - section on "Removing" 481519 Removing and installing steering column centre
11. Remove alarm horn. -> 966519 Removing and installing alarm siren - section on "Removing" Service and Repair
Removing dashboard support
Installation position of dashboard support
Information
Only for USA/Canada version vehicles
1. Unscrew fastening screws -1- and remove knee protector -2-.
Removing knee protector
2. Push out fixing clip -1- and unclip length compensation -2-.
Removing length compensation
3. Undo fastening nuts -1- and place ground straps -2- to one side.
Loosening ground straps
4. Cut tie-wraps -1- on main wire harness.
Cutting tie-wraps
5. Unscrew fastening screw -1- on bracket for heater housing -2-.
Removing bracket for heater housing
6. Undo fastening nuts -1- close to the plenum panel.
Releasing dashboard support
7. Unscrew fastening screws at the left and right -1- on the dashboard support -2-.
Releasing dashboard support
8. Unscrew left fastening screw -1- and remove bracket -2-.
Releasing dashboard support
9. Unscrew right fastening screw -1- and pull dashboard support -3- out slightly.
10. Unclip cable guide -1- on left of dashboard support using a screwdriver.
Unclipping cable guide
11. Unclip cable guide -1- on dashboard support from below -Inset-.
Unclipping cable guide
12. Unclip cable guide -1- at the back of the dashboard support using a screwdriver.
Unclipping cable guide
13. Unclip wire harness with fixing clip -1, 2- on dashboard support.
Unclipping wire harness
14. Unclip cable guide -1- on right of dashboard support using a screwdriver.
Unclipping cable guide
15. Release locking lug -Arrow A- and unclip cable guide -1- on bottom right of dashboard support in an upward direction -Arrow B-.
Unclipping cable guide
Information
When removing the dashboard support, make sure that wires or plug connections are not damaged.
16. Get another person to help you remove the dashboard support carefully in an upward direction.
Replacing bracket for dashboard support
- Removing bracket for dashboard support
Removing bracket for dashboard support
Mark position of bracket -2- with respect to the body.
Undo fastening nuts -1- and remove bracket -2-.
- Installing bracket for dashboard support
Installing bracket for dashboard support
Position bracket -2- according to the marks you made and secure in place with fastening nuts -1-. => Tightening torque: 23 Nm (17 ftlb.)
Installing dashboard support
1. Screw on nut for tolerance compensation -2- on dashboard support -1- to the dimension -X= 35 mm-.
Screwing on nut for tolerance compensation
Information
When positioning the dashboard support, make sure that wires or plug connections are not jammed.
2. Get another person to help you position the dashboard support in such a way that the wire harnesses can be clipped in.
3. Align and route wire harness and plug connections.
4. Clip in cable guide -1- at the bottom right of the dashboard support.
Clipping in cable guide
5. Clip in cable guide -1- at the right of the dashboard support.
Clipping in cable guide
6. Clip wire harness onto dashboard support with a fixing clip -1, 2-.
Clipping in wire harness
7. Clip in cable guide -1- at the back of the dashboard support.
Clipping in cable guide
8. Clip in cable guide -1- at the left of the dashboard support.
Clipping in cable guide
9. Clip in cable guide -1- at the top left of the dashboard support.
Clipping in cable guide
Information
Before securing the dashboard support, make sure that all lines and plug connections are routed correctly.
10. Fully position dashboard support -2- and screw fastening screws in by hand at the left and right -1-.
Securing dashboard support
11. Align dashboard support and tighten fastening screws at the left and right -1-. => Tightening torque: 23 Nm (17 ftlb.)
12. Secure dashboard support -3- at the right with the fastening screw -1-. => Tightening torque: 9.7 Nm (7.5 ftlb.)
Securing dashboard support
13. Position bracket -2- and secure with the fastening screw -1-. => Tightening torque: 9.7 Nm (7.5 ftlb.)
14. Tighten fastening nuts -1- close to the plenum panel. => Tightening torque: 23 Nm (17 ftlb.)
Securing dashboard support
15. Tighten fastening screw -1- on bracket for heater housing -2-. => Tightening torque: 3.5 Nm (2.5 ftlb.)
Securing bracket for heater housing
16. Secure main wire harness using new tie-wraps -1-.
Securing main wire harness
17. Fit ground straps -2- and secure in place with fastening nuts -1-. => Tightening torque: 9.7 Nm (7.5 ftlb.)
Fastening ground straps
18. Position length compensation -2- on dashboard support and secure in place with the fixing clip -1-.
Installing length compensation
Information
Only for USA/Canada version vehicles
19. Position knee protector -2- on dashboard support and secure in place with fastening screws -1-. => Tightening torque: 9.7 Nm (7.5 ftlb.)
Installing knee protector
Subsequent work
1. Install alarm horn. -> 966519 Removing and installing alarm siren - section on "Installing" Service and Repair
2. Lock steering column plug connection and install steering column. -> 481519 Removing and installing steering column - section on "Installing" 481519 Removing and installing steering column centre
3. Install brake pedal. -> 460519 Removing and installing brake pedal - section on "Installing" Service and Repair
4. Install brake light switch. -> 943619 Removing and installing brake light switch - section on "Installing" Service and Repair
Information
Only for vehicles with manual transmission.
5. Install clutch pedal. -> 300519 Removing and installing clutch pedal - section on "Installing" Service and Repair
6. Install control unit for KESSY/PAS. -> 966619 Removing and installing KESSY/PAS control unit - section on "Installing" Service and Repair
7. Install vehicle electrical system control unit with bracket. -> 971019 Removing and installing vehicle electrical system control unit - section on "Installing" Service and Repair
8. Install relay carrier 1. -> 978319 Removing and installing relay carrier 1 - section on "Installing" 97831900 Removing and installing relay carrier 1
9. Install tunnel support. -> 684419 Tunnel support - section on "Installing" 68441900 Removing and installing tunnel support
10. Install air guides. -> 853419 Removing and installing air guide - section on "Installing" 85341900 Removing and installing air guide
11. Install dashboard. -> 701819 Removing and installing dashboard - section on "Installing" 701819 Removing and installing instrument panel