Lincoln Corsair: Instrument Panel and Console / Removal and Installation - Instrument Panel

Special Tool(s) / General Equipment

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Evacuate the refrigerant.
   Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant (412-00 Climate Control System - General Information) .
   Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R1234YF Refrigerant (412-00 Climate Control System - General Information) .
   

1. Drain the coolant.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
   

1. Remove the air cleaner outlet pipe.
   Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   

1. Remove the battery tray.
   Refer to: Battery Tray - 2.0L EcoBoost (177kW/240PS) – MI4/2.3L EcoBoost (199kW/270PS) (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the battery tray reinforcment.
   

1. Detach the cable retainer, remove the bolts and the battery tray reinforcment bracket.
   Torque: 133 lb.in (15 Nm)

1. Postion the grommit forward on the heater hose.
   

1. Remove the nuts and the center cowl insulation panel.
   Torque: 71 lb.in (8 Nm)

1. Pinch the hoses, remove the clamps and position aside.
   

1. Remove the retainers and the thermostatic expansion valve cover.
   

1. Remove the nut and remove the HVAC flange.
   

1. Remove the wiper linkage assembly.
   Refer to: Wiper Linkage Assembly (501-16 Wipers and Washers, Removal and Installation).
   

1. Remove the bolts.
   Torque: 18 lb.ft (25 Nm)

1. Release the clips and remove the LH trim panel.
   

1. Release the clips and remove the LH trim panel.
   

1. Release the clips and remove the LH lower A-pillar trim panel.
   

1. 1. Remove the hood release handle.
      
   2. Release the clips and remove the LH scuff plate.
      
   3. Disconnect the electrical connector.
      

1. • Remove the cover.
     
   • Remove the nut and the foot rest pad.
     Torque: 48 lb.in (5.4 Nm)

1. Release the clips and remove the RH trim panel.
   

1. Release the clips and remove the RH trim panel.
   

1. Release the clips and remove the lower RH A-pillar trim panel.
   

1. 
   Release the clips and remove the RH scuff plate.
   
   • Disconnect the electrical connectors.
     

1. Remove the floor console.
   Refer to: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
   

1. Remove the driver side front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

1. Remove the A-pillar trim panels.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Disconnect the LH A-pillar electrical connector.
   

1. Disconnect the RH A-pillar electrical connector.
   

1. 
   Remove the bolt, release the clips and pull rearward to remove the defroster grille trim panel.
   
   • Disconnect the electrical connecter at the RH A-pillar.
     Use the General Equipment: Interior Trim Remover

1. Remove the instrument panel-to-cowl bolt.
   Torque: 22 lb.in (2.5 Nm)

1. Position aside the carpet.
   

1. Disconnect the electrical connectors, release the harness retainers and position aside the harness.
   

1. Remove the retainers and remove the foam pad.
   

1. Disconnect the electrical connectors and release the harness retainers.
   

1. Remove the nuts and the BCM .
   Torque: 59 lb.in (6.7 Nm)

1. Remove the nut.
   Torque: 59 lb.in (6.7 Nm)

1. 1. Remove the cover.
      
   2. Lift the cable strap upward and rearward to disengage from the lower trim panel.
      

1. NOTICE: Do not allow the steering wheel to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, remove and recenter the clockspring.

   Secure the steering wheel.
   

1.   WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   1. Remove and discard the steering shaft coupler retainer.
      Torque:
        Stage 1:  35 lb.ft (48 Nm)
        Stage 2:  120°
   2. Separate the steering column shaft from the steering column.
      

1. NOTE: Lower left hand side.

   Disconnect the electrical connectors, and detach the harness retainers.
   

1. • Remove the cover.
     
   • Remove the bolt.
     Torque: 18 lb.ft (25 Nm)

1. Remove the nuts and the bracket.
   Torque: 18 lb.ft (25 Nm)

1. Remove the nuts and the bracket.
   Torque: 18 lb.ft (25 Nm)

1. Remove the HVAC ducts.
   

1. NOTE: Leave the top bolt finger tight until ready to remove the instrument panel.

   Remove the bolts.
   Torque: 35 lb.ft (47.5 Nm)

1. NOTE: Leave the top bolt finger tight until ready to remove the instrument panel.

   Remove the bolts.
   Torque: 35 lb.ft (47.5 Nm)

1. NOTE: To avoid damaging the instrument panel, an assistant is required when carrying out this step.

   NOTE: Make sure not to damage the instrument panel when removing the instrument panel from the vehicle.

   NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the instrument panel or damage to the components may occur.

   Remove the instrument panel.
   

Installation

1. To install, reverse the removal procedure.
   

1. Fill and bleed the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).