Firewall: Service and Repair
WM 501451 Sealing front panel
Technical values
Preliminary work
1. Disconnect battery. -> 2706IN Work instructions after disconnecting the battery Procedures
2. Lift the vehicle. -> 40 Lifting the vehicle
3. Remove the cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Removing" 390219 Removing and installing front cardan shaft
4. Remove primary catalytic converter. -> 267619 Removing and installing primary catalytic converter - section on "Removing" 267620 Removing and installing primary catalytic converters on 3.6-litre V6 DFI engines
5. Remove wiper motor. -> 921519 Removing and installing wiper motor - section on "removing" 921519 Removing and installing wiper motor
6. Remove DME control module. -> 247019 Removing and installing DME control module - section on "Removing" 247019 Removing and installing DME (DFI) control unit
7. Remove alarm siren. -> 966519 Removing and installing alarm siren - section on "Removing" Service and Repair
Sealing front panel
Removing support for DME control module
1. Screw down fastening nut -1- and take off ground strap with the twist lock.
Loosening ground straps
2. Open the retaining clips -arrow A- and take out the DME control module wire harness -arrow B-.
Removing support for DME control module
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-.
Removing intake pipe on the heating/fresh air unit
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
Installation position of firewall plate on front panel
1. Unclip wire harness -A- in plenum panel and lay it to one side and to the front.
Wire harness in plenum panel
2. Remove left and right heat shield (above the catalytic converters).
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).
Sealing front panel
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).
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.
Wire harness in plenum panel
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.
Installing intake pipe on the heating/fresh air unit
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.
Installing support for DME control module
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.
Fastening ground straps
Subsequent work
1. Check connection points on main wire harness for corrosion and rework if necessary. -> 970949 Reworking main wire harness - section on "Reworking" 970949 Reworking Main Wire Harness
2. Install alarm siren. -> 966519 Removing and installing alarm siren - section on "Installing" Service and Repair
3. Install DME control module. -> 247019 Removing and installing DME control module - section on "Installing" 247019 Removing and installing DME (DFI) control unit
4. Install wiper motor. -> 921519 Removing and installing wiper motor - section on "installing" 921519 Removing and installing wiper motor
5. Install primary catalytic converter. -> 267619 Removing and installing primary catalytic converter - section on "Installing" 267620 Removing and installing primary catalytic converters on 3.6-litre V6 DFI engines
6. Install cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Installing" 390219 Removing and installing front cardan shaft
7. Lower the vehicle. -> 40 Lifting the vehicle
8. Carry out work instructions after disconnecting the battery. -> 2706IN Work instructions after disconnecting the battery Procedures