Firewall: Service and Repair

Sealing front panel

Technical values







Preliminary work

1. Disconnect battery. Refer to Work instructions after disconnecting the battery
2. Lift the vehicle. Refer to Lifting the vehicle
3. Remove the cardan shaft. Refer to Removing and installing front cardan shaft.
4. Remove primary catalytic converter. Refer to Removing and installing primary catalytic converter.
5. Remove wiper motor. Refer to Removing and installing wiper motor.
6. Remove DME control module. Refer to Removing and installing DME control module.
7. Remove alarm siren. Refer to Removing and installing alarm siren.

Sealing front panel

Removing support for DME control module

1. Screw down fastening nut -1- and take off ground strap with the twist lock.







2. Open the retaining clips -arrow A- and take out the DME control module wire harness -arrow B-.







3. Unscrew the fastening screw -2- and the two fastening nuts -3- and take out the support for the DME control module.

Removing intake pipe on the heating/fresh air unit

1. Pull out wire harness retaining clips on the intake manifold -arrow A- and unclip the wire harness on the intake manifold -arrow B-.







2. Pull out air inlet grille -arrow C-.
3. Open both retaining clips in the intake manifold -arrow D-.
4. Unscrew the two fastening nuts -1- and remove the intake manifold.

Sealing front panel







1. Unclip wire harness -A- in plenum panel and lay it to one side and to the front.







2. Remove left and right heat shield (above the catalytic converters).







2.1. Unscrew fastening nuts and fastening screw -A- on the right and left heat shield.
2.2. Remove left and right heat shield.

DANGER: Danger of injury.
- Wear suitable protective clothing.
- Observe warnings on the isopropanol and body sealant containers.
- Avoid contact with the skin and eyes.

INFORMATION: After cleaning with isopropanol, a ventilation period of approx. 30 minutes must always be observed.

3. Clean surrounding edge between the firewall plate and the front panel from the outside, in the area shown -arrows-, at the edge with cleaning agent (isopropanol).







DANGER: Danger of injury.
- Wear suitable protective clothing.
- Observe warnings on the isopropanol and body sealant containers.
- Avoid contact with the skin and eyes.

INFORMATION: When sealing the firewall plate, ensure without fail that the water drains in the air-conditioning system are not blocked with sealant.

4. Seal firewall plate from the outside, in the area shown -arrows-, at the edge between the firewall plate and front panel, all the way round with Sikaflex-529 body sealant, 000.043.206.36.
5. Install left and right heat shield (above the catalytic converters).







5.1. Position left and right heat shield.
5.2. Screw on left and right heat shield plate using the fastening nuts and fastening screw -A- on the left and right heat shield plate.

6. Route wire harness -A- in the plenum panel and clip it in.







Installing intake pipe on the heating/fresh air unit

1. Position intake manifold and secure with both fastening nuts -1-.
Tightening torque: 4.5 ftlb.







2. Close both retaining clips in the intake manifold -arrow A-.
3. Insert air inlet grille -arrow B-.
4. Clip in wire harness to intake manifold -arrow C- and insert wire harness retaining clips on intake manifold -arrow D-.

Installing support for DME control module

1. Position support for DME control module and screw down both fastening nuts -3- and the fastening screw -2-.
Tightening torque: 6 ftlb.
Tightening torque: 6 ftlb.







2. Insert DME control module in the retaining clips -arrow A- and close the retaining clips -arrow B-.
3. Mount ground straps together with the twist lock on the stud and screw down with the fastening nut -1-.
Tightening torque: 6.5 ftlb.







Subsequent work

1. Check connection points on main wire harness for corrosion and rework if necessary. Refer to Reworking main wire harness.
2. Install alarm siren. Refer to Removing and installing alarm siren.
3. Install DME control module. Refer to Removing and installing DME control module.
4. Install wiper motor. Refer to Removing and installing wiper motor.
5. Install primary catalytic converter. Refer to Removing and installing primary catalytic converter.
6. Install cardan shaft. Refer to Removing and installing front cardan shaft.
7. Lower the vehicle. Refer to Lifting the vehicle
8. Carry out work instructions after disconnecting the battery. Refer to Work instructions after disconnecting the battery