Fascia Assembly - Vehicles Without Single Point Sensed SRS

Fascia Assembly - Vehicles Without Single Point Sensed SRS

Service Repair No - 76.46.23/99

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. Vehicles with SRS only: Remove battery.
2. Vehicles without SRS: Disconnect battery negative lead.
3. Drain cooling system.



4. Loosen hose clips, disconnect hoses from heater pipes.
5. Remove center console.
6. Remove steering column.
7. Remove wiper motor and linkage.
8. Disconnect passenger side heated front screen multiplug. Release multiplug from clip.



9. Remove 6 bolts, remove remaining scuttle side panel.
10. Remove heater intake pollen filters.



11. Remove 8 screws securing each pollen filter housing. Remove both housings.
12. Remove radio.



13. Release door aperture seal adjacent to 'A' post lower trim panels.
14. Driver's side - LHD automatic vehicles only:
^ Remove 3 bolts securing foot rest through 'A' post lower trim, remove toot rest.



15. Remove screw securing each 'A' post lower trim panel, release from single sprag clip, remove both trim panels.



16. Remove fuse cover from driver's seat base trim.
17. Remove screw and 2 trim studs, remove seat base trim.



18. Release 4 sprag clips, remove driver's side carpet retainer.
19. Remove 2 scrivet fasteners securing lower closing panel to passenger side of fascia.



20. Release closing panel, disconnect footwell lamp, release diagnostic multiplug. Remove closing panel.



21. Remove 4 bolts, remove fascia center bracket.



22. Disconnect 4 multiplugs from Body Electrical Control Module (BeCM)
23. Remove captive nut, remove earth wires from stud at base of driver's side 'A' post.



24. Disconnect multiplugs at base of each 'A' post.
25. Release BeCM harness from sill, route into fascia to prevent fouling as fascia is removed.



26. Disconnect multiplugs and release vacuum hose from brake and clutch switches.
27. Models with SRS only: Disconnect SRS multiplug from main harness.



28. Disconnect multiplug from SRS control module, route harness into fascia to prevent fouling as fascia is removed.
29. Remove both front wheel arch liners.



30. Remove 2 scrivet fasteners securing air cleaner baffle beneath LH wheel arch. Remove baffle.



31. Disconnect both SRS crash sensor multiplugs.



32. Remove 4 bolts securing battery tray and 2 bolts securing air cleaner to valance.
33. Raise air cleaner and battery tray for access to crash sensor harness clips.



34. Release clips securing each crash sensor harness to valance. Release harness grommets and feed both harnesses through valance into wheel arches.
35. Release 3 clips securing each crash sensor harness to underside of wheel arches.
36. Release harness grommets, feed harnesses through bulkhead and route into fascia to prevent fouling as fascia is removed.
37. Vehicles with air conditioning only:
^ Discharge air conditioning system.



38. Remove bolt securing pipe clamp to Thermostatic Expansion Valve (TXV).
39. Release pipes from TXV and remove '0' rings. Seal pipes and ports of TXV.



40. All models: Remove 4 tube bolts securing fascia to scuttle panel.



41. Remove nuts and washers securing fascia to base of 'A' posts.
42. Remove bolt securing fascia to pedal box.
43. Using assistance, carefully maneuver the fascia through the driver's door aperture. Place fascia on a soft covered work surface, supported on suitable wooden blocks.
44. Remove rubber seals from air intake ducts.
45. Collect rear heater duct connecting tubes.

Refit

46. Fit intake seals to blower motor ducts. Tape rubbers inside blower ducts to aid fitment.

NOTE: Tape the rubbers at this stage, as they are almost impossible to locate after dash fitment.

47. Fit guide pins LRT-76-OO1 to outer fascia studs.
48. With assistance, maneuver fascia into position through driver's front door aperture. Locate guide pins.

NOTE: Assistance from a third person may be necessary when guiding heater pipes through bulkhead.

49. Loosely fit 1 tube bolt, fascia to scuttle.
50. Fit bolt securing fascia to pedal box.
^ Tighten to 25 Nm (18 ft.lbs)
51. Fit nuts and washers at base of A posts.
^ Tighten to 25 Nm (18 ft.lbs)
52. Remove guide pins.
53. Fit remaining tube bolts.
^ Tighten to 25 Nm (18 ft.lbs)
54. Fit rear heater duct connecting pipes.
55. Remove tape from intake seals.
56. Engage lips of sealing rubbers around scuffle apertures.
57. Fit pollen filter housings, tighten bolts.
58. Fit scuttle side panel to passenger side of vehicle, tighten bolts.
59. Connect heated screen multiplug, fit to side panel clip.
60. Connect hoses to heater pipes. Tighten clips.
61. Air conditioning vehicles: Remove seals from air conditioning pipes and TXV ports.
62. Lubricate new 0 rings with clean compressor oil, fit to pipes.
63. Locate pipes in TXV ports, position clamp and fit clamp bolt.
64. Engage evaporator drain tubes over pipes in transmission tunnel.
65. Vehicles with SRS only: Route SRS crash sensor harnesses through bulkhead into wheel arches, locate harness grommets.
66. Secure harness clips beneath wheel arches, route harnesses through valances into engine bay, locate harness grommets.
67. Raise battery tray and air cleaner for access. Route crash sensor harnesses, secure harness clips, connect multiplugs to crash sensors.
68. Tighten battery tray and air cleaner bolts.
69. Connect multiplug to SRS control module.
70. Connect SRS harness multiplug to main harness.
71. Fit air cleaner baffle beneath LH wheel arch, secure with scrivet fasteners.
72. Fit wheel arch liners.
73. All models:Route harness along sill, connect multiplugs to BeCM
74. Connect multiplugs at base of 'A' posts and secure plugs to brackets.
75. Fit earth wires to stud, tighten captive nut.
76. Connect vacuum hose and multiplugs to brake and clutch pedal switches.
77. Position closing panel beneath passenger side of fascia. Secure diagnostic plug, connect footwell lamp. Align closing panel, secure with scrivet fasteners.
78. Fit carpet retainer, engage sprag clips.
79. Fit seat base trim panel, secure trim studs, tighten screw.
80. Fit fuse cover to seat base trim.
81. Fit both 'A' post lower trim panels, secure sprag clips. Engage door aperture seals.
82. LHD automatic vehicles only:
^ Fit foot rest, secure with bolts.
83. Fit radio.
84. Fit wiper motor and linkage.
85. Fit steering column.
86. Fit center console.
87. Refill cooling system.
88. Vehicles with SRS only: Fit battery.
89. Reconnect battery negative lead.
90. Evacuate and recharge air conditioning.