51 45 050 Removing and installing instrument panel upper section trim (from 07/04)

Necessary Preliminary Tasks:

Remove glovebox. Refer to 51 16 360 REMOVING AND INSTALLING RIGHT GLOVEBOX .
Remove decorative trims for instrument panel. Refer to 51 45 066 REMOVING AND INSTALLING DECORATIVE TRIM FOR INSTRUMENT PANEL (DRIVER'S SIDE) and 51 45 068 REMOVING AND INSTALLING DECORATIVE TRIM FOR INSTRUMENT PANEL (PASSENGER SIDE) .

Lever out cover on left and right in direction of arrow.

Fig 1: Locating Decorative Trims For Instrument Panel

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With passenger airbag deactivation optional extra only:

Unlock plug connections (1) and disconnect.

Fig 2: Identifying Plug Connections

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Release left and right screws (1).

Fig 3: View Of Retaining Screws

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Release screws (1).

Fig 4: Identifying Retaining Screws

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Release screws (1).

Fig 5: Locating Retaining Screws

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Lever out cover caps (1) in ventilation grille and release screws underneath.

Fig 6: View Of Cover Caps In Ventilation Grille

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Release screws (1) in ventilation grille.

Fig 7: Identifying Screws In Ventilation Grille

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With automatic air conditioning optional extra only:

NOTE: Tape off work area around solar sensor (1) (risk of damage).

Remove solar sensor (1).

Firmly pull solar sensor (1) upwards to release binding (adhesive tape inside instrument panel).

Feed plug connection (2) out of instrument panel and disconnect.

Installation:

Wrap adhesive tape round plug connection to prevent rattling noises.

Fig 8: Disconnecting Plug Connection Out Of Instrument Panel

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Fig 9: Identifying Broken Eyelet

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IMPORTANT: Broken eyelets (5) or damaged restraint cables (2) can cause injuries due to uncontrolled tearing off of the airbag covers when airbags are triggered. Instrument panel upper section trim must be replaced if eyelets (5) are damaged or restraint cables (2) are damaged. In order to prevent damage to eyelets (5), make sure spacer (4) is fitted; retrofit if necessary.

Release screws (1).

Tightening torque, (6 N.m.).

Remove instrument panel upper section towards top and feed out restraint cables (2) between airbag module and instrument panel lower section.

Installation:

Restraint cables (2) must be located between bracket (3).

Installation:

Insert restraint cables in gap between airbag module and instrument panel lower section.

Fig 10: Identifying Gap Between Airbag Module And Instrument Panel Lower Section

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Installation:

Insert centering pin of instrument panel upper section correctly into locator (1).

Lift instrument panel upper section in front area over guides (2).

Push in instrument panel upper section as far as it will go.

Fig 11: View Of Locator For Centering Pin

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IMPORTANT: Do not strike area (1) of instrument panel upper section with fist. Laser seam of airbag cover must now show in foam film.

Fig 12: Identifying Laser Seam Of Airbag

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Replacement Only:

Build date from 03/04 - 07/04:

Air duct cutout must be adapted for a new instrument panel upper section.

Cut out instrument panel in marked area (2).

Lay wiring harness (1) between instrument panel and bulkhead.

Fig 13: Laying Wiring Harness Between Instrument Panel And Bulkhead

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