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In-Vehicle Crossbeam: Installation

  1. NOTE: To avoid damaging the RH door trim panel when installing the in-vehicle cross beam into the vehicle, an assistant is required when carrying out this step.
    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. Connect the small RCM  electrical connector and attach the wire harness pin-type retainers.
    Fig 1: Measuring Voltage Between SJB C2280G-1, Circuit SBB01 (RD), Harness Side And Ground
    G06071040Courtesy of FORD MOTOR CO.
  9. Install the ground wires and the 2 bolts to the floor pan tunnel.
    • Tighten to 10 Nm (89 lb-in).
    Fig 2: Locating Ground Wires And Bolts
    G06071039Courtesy of FORD MOTOR CO.
  10. Connect the RH bulkhead electrical connector, antenna cable and if equipped, the satellite radio connector.
    Fig 3: Locating RH Bulkhead Electrical Connector, Antenna Cable And Satellite Radio Connector
    G06071038Courtesy of FORD MOTOR CO.
  11. If equipped, install the rear footwell duct and the 2 pin-type retainers.
    Fig 4: Locating Rear Footwell Duct And 2 Pin-Type Retainers
    G06071044Courtesy of FORD MOTOR CO.
  12. Install the LH and RH front carpet sections.
    • Install the 2 pin-type retainers.
  13. Install the driver footrest pad.
    • Install the 2 pin-type retainers.
    Fig 5: Locating 2 Pin-Type Retainers And Driver Footrest Pad
    G06071036Courtesy of FORD MOTOR CO.
  14. Install the steering column shaft to the steering column.
  15. Install a new steering column shaft-to-steering column bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 6: Locating Steering Column Shaft-To-Steering Column Bolt
    G06071046Courtesy of FORD MOTOR CO.
  16. Connect the 2 SJB  electrical connectors and the lower bulkhead electrical connector.
    Fig 7: Locating SJB Electrical Connectors And Lower Bulkhead Electrical Connector
    G06071101Courtesy of FORD MOTOR CO.
  17. Connect the LH bulkhead electrical connector.
    Fig 8: Locating LH Bulkhead Electrical Connector
    G06071033Courtesy of FORD MOTOR CO.
  18. Install the instrument panel upper section. For additional information, refer to INSTRUMENT PANEL UPPER SECTION 
  19. Install the PCM bracket.
    • Install and tighten the 3 PCM bracket nuts.
    Fig 9: Locating PCM Bracket Nuts
    G06071022Courtesy of FORD MOTOR CO.
  20. Install the PCM.
    • Install and tighten the 2 PCM nuts.
    • Tighten to 5 Nm (44 lb-in).
    Fig 10: Locating PCM Nuts
    G06071051Courtesy of FORD MOTOR CO.
  21. Install the wire harness retainer onto the PCM bracket stud.
    Fig 11: Locating Wire Harness Retainer Onto PCM Bracket Stud
    G06071020Courtesy of FORD MOTOR CO.
  22. Connect the 3 PCM electrical connectors.
  23. Install the front seats. For additional information, refer to SEATING .
  24. Install the TXV  manifold in the follow sequence.
    1. Install new O-ring seals.
    2. Install and tighten the TXV  manifold bolt.
      • Tighten to 8 Nm (71 lb-in).
    Fig 12: Locating TXV Manifold Bolt
    G06071031Courtesy of FORD MOTOR CO.
  25. Install the heater hoses onto the heater core.
    Fig 13: Locating Heater Hoses Onto Heater Core
    G06071030Courtesy of FORD MOTOR CO.
  26. Install the heater hoses onto the heater hose tubes.
    Fig 14: Locating Heater Hoses Onto Heater Hose Tubes
    G06071029Courtesy of FORD MOTOR CO.
  27. Install the heater hose separator.
    Fig 15: Locating Heater Hose Separator
    G06071056Courtesy of FORD MOTOR CO.
  28. Install the ACL  outlet pipe.
    • Tighten the ACL  outlet pipe-to-throttle body clamp and the ACL  outlet pipe-to- ACL  cover clamp.
    Fig 16: Locating ACL Outlet Pipe-To-Throttle Body Clamp And ACL Outlet Pipe-To- ACL Cover Clamp
    G06071110Courtesy of FORD MOTOR CO.
  29. Install the crankcase vent tube and the vacuum tube onto the ACL outlet pipe.
    Fig 17: Locating Crankcase Vent Tube And Vacuum Tube
    G06071026Courtesy of FORD MOTOR CO.
  30. Connect the vacuum hose and the evaporator purge solenoid hose to the upper intake manifold.
    Fig 18: Locating Vacuum Hose And Evaporator Purge Solenoid Hose
    G06071080Courtesy of FORD MOTOR CO.
  31. Install the strut tower cross brace.
    • NOTE: LH side shown in illustration, RH side similar.

    Install the LH and RH strut upper mount nuts.

    • Tighten to 30 Nm (22 lb-ft).
    Fig 19: Locating Strut Upper Mount Nuts
    G06071024Courtesy of FORD MOTOR CO.
  32. Install the vacuum hose clip onto the strut tower cross brace.
    Fig 20: Locating Vacuum Hose Clip
    G06071023Courtesy of FORD MOTOR CO.
  33. Install the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS AND WASHERS .
  34. Charge the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  35. Fill the cooling system. For additional information, refer to ENGINE COOLING .
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