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 PCM 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. Remove the strut tower cross brace.
- NOTE: LH side shown, RH side similar.

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 heater hoses from the heater core.





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





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

15. Remove the front seats.

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

17. Remove the LH and RH front door opening weatherstrips.

18. Remove the LH and RH scuff plate trim panels.
- Lift the scuff plate trim panels upward to release the retaining clips.

19. Remove the LH and RH lower cowl trim panels.
- Pull the lower cowl trim panels rearward to release the retaining clips.

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





21. Detach the steering column shaft from the steering column.

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





25. 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.

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





27. Disconnect the antenna cable and if equipped, the satellite radio antenna connector.





28. Disconnect the RH bulkhead electrical connector.





29. Remove the 2 bolts and the ground wires from the floor pan tunnel.





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





31. Detach the 2 wire harness pin-type retainers from the RH instrument panel center support bracket.





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 completely and support the in-vehicle cross beam before removing the bolts from the opposite side.

Remove the 6 instrument panel side bolts.

34. NOTICE: To avoid damaging the door trim panel, an assistant is required when carrying out this step.

NOTICE: Make sure not to damage the RH front door trim panel when removing the in-vehicle cross beam from the vehicle.

NOTE: Make sure that the electrical connectors and wiring are not caught up on other components before removing the in-vehicle cross beam.

Remove the in-vehicle cross beam from the vehicle.

Installation

1. NOTICE: To avoid damaging the door trim panel, an assistant is required when carrying out this step.

NOTICE: Make sure not to damage the RH front door trim panel when installing the in-vehicle cross beam into the vehicle.

NOTE: Make sure that all electrical connectors and wiring are correctly routed when installing the in-vehicle cross beam.

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. Attach the 2 wire harness pin-type retainers onto the RH instrument panel center support bracket.





9. Connect the small RCM electrical connector and attach the wire harness pin-type retainers.





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





11. Connect the RH bulkhead electrical connector.





12. Connect the antenna cable and if equipped, the satellite radio connector.





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





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

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





16. Connect the 2 SJB electrical connectors and the lower bulkhead electrical connector.





17. Connect the LH bulkhead electrical connector.





18. Install the steering column shaft to the steering column.

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





20. Install the RH and LH lower cowl trim panels.
- Make sure to align the lower cowl trim panel retaining clips to the retaining clip holes in the body.

21. Install the RH and LH scuff plate trim panels.
- Make sure to align the scuff plate trim panel retaining clips to the retaining clip holes in the body.

22. Install the RH and LH front door opening weatherstrips.

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

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





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





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





27. Connect the 3 PCM electrical connectors.

28. Install the front seats.

29. Install the TXV manifold in the following sequence.

1. Install new O-ring seals.

2. Install and tighten the TXV manifold bolt.
- Tighten to 8 Nm (71 lb-in).





30. Connect the heater hoses to the heater core.





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





32. 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).





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





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

35. Charge the refrigerant.

36. Fill the cooling system.