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Home >> Ford >> 2011 >> Flex SE >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panel >> Removal And Installation >> In-Vehicle Crossbeam >> Installation

In-Vehicle Crossbeam: Installation

    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 or damage to the components may occur.
  1. 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: Locating Restraints Control Module (RCM) Small Electrical Connector And Wire Harness Pin-Type Retainers
    G07466825Courtesy 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 Bolts
      G07466826Courtesy 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 Antenna Connector
    G07466827Courtesy of FORD MOTOR CO.
  11. If equipped, install the rear footwell duct and the 2 pin-type retainers.
    Fig 4: Locating Rear Footwell Duct Pin-Type Retainers
    G07466828Courtesy of FORD MOTOR CO.
  12. Install the LH and RH front carpet portions.
    • Install the 2 pin-type retainers.
  13. Install the driver footrest pad.
    • Install the 2 pin-type retainers.
      Fig 5: Locating Driver Footrest Pad And Pin-Type Retainers
      G07466829Courtesy 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
      G07466830Courtesy of FORD MOTOR CO.
  16. Connect the 2 SJB  electrical connectors and the lower bulkhead electrical connector.
    Fig 7: Locating Smart Junction Box (SJB) Lower And Lower Bulkhead Electrical Connectors
    G07466831Courtesy of FORD MOTOR CO.
  17. Connect the LH bulkhead electrical connector.
    Fig 8: Locating LH Bulkhead Electrical Connector
    G07466832Courtesy of FORD MOTOR CO.
  18. Install the instrument panel upper part. For additional information, refer to INSTRUMENT PANEL UPPER SECTION  in this information.
  19. Install the PCM bracket.
    • Install and tighten the 3 PCM bracket nuts.
      Fig 9: Locating PCM Bracket Nuts
      G07466833Courtesy 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
        G07466834Courtesy of FORD MOTOR CO.
  21. Install the wire harness retainer onto the PCM bracket stud.
    Fig 11: Locating PCM Bracket Stud
    G07466835Courtesy of FORD MOTOR CO.
  22. Connect the 3 PCM electrical connectors.
  23. Install the front seats. For additional information, refer to SEAT SYSTEM .
  24. Install the TXV  manifold in the following sequence.
    1. Install new O-ring seals.
    2. Install and tighten the TXV  manifold fastener.
      • Tighten to 8 Nm (71 lb-in).
        Fig 12: Locating Thermostatic Expansion Valve (TXV) Manifold And Fastener
        G07466836Courtesy of FORD MOTOR CO.
  25. Install the heater hoses onto the heater core.
    Fig 13: Locating Heater Hoses Of Heater Core
    G07466837Courtesy of FORD MOTOR CO.
  26. Install the heater hoses onto the heater hose tubes.
    Fig 14: Locating Heater Hoses
    G07466838Courtesy of FORD MOTOR CO.
  27. Install the heater hose separator.
    Fig 15: Locating Heater Hose Separator
    G07466839Courtesy of FORD MOTOR CO.
  28. Install the ACL  outlet pipe.
    • Tighten the ACL  outlet pipe-to- TB  clamp and the ACL  outlet pipe-to- ACL  cover clamp.
      Fig 16: Locating ACL Outlet Pipe-To-Throttle Body (TB) And ACL Outlet Pipe-To-ACL Cover Clamps
      G07466840Courtesy of FORD MOTOR CO.
  29. Install the crankcase vent tube and the vacuum tube onto the ACL  outlet pipe.
    Fig 17: Locating Crankcase Vent And Vacuum Tubes
    G07466841Courtesy 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
    G07466842Courtesy of FORD MOTOR CO.
  31. Install the strut tower cross brace.
      NOTE: LH side shown in the illustration, RH side similar.
    • Install the LH and RH strut upper mount nuts.
      • Tighten to 30 Nm (22 lb-ft).
        Fig 19: Locating LH And RH Strut Upper Mount Nuts
        G07466843Courtesy of FORD MOTOR CO.
  32. Install the vacuum hose clip onto the strut tower cross brace.
    Fig 20: Locating Vacuum Hose Clip
    G07466844Courtesy of FORD MOTOR CO.
  33. Install the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPER SYSTEM & WASHER SYSTEM .
  34. Charge the refrigerant. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  35. Fill the cooling system. For additional information, refer to ENGINE COOLING SYSTEM .
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