Removal and installation of the instrument panel 4.4L (Discovery 3)

Removing

1. Remove the engine cover. For more information refer to Engine Cover - 4.4L (12.30.50)

2. Evacuate the air conditioning system. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)

3.

WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.

Raise the car and place it on stands.

4. Drain the liquid from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

5. Remove the floor console. For more information refer to Floor Console (76.25.01)

6. Remove both doorway trim panels. For more information refer to Front Doorway Trim Panel (76.13.27)

7. Remove the decorative panel from the driver's side.

• Release the clamp.
• Remove 2 screws.
• Disconnect the electrical connector.

8. Remove the decorative panel from the passenger side.

• Release the clamp.
• Remove 2 screws.
• Disconnect the electrical connector.

9. Disconnect the limiter of opening of a door from a forward rack of a body. Remove 2 Torx head screws.




10.

NOTE: At this stage, the door is still secured with the appropriate fasteners.

With assistance, release the door assembly and place it on the supports. Turn out 2 bolts.



11. Disconnect electrically the connector from the A-pillar.

• Remove the sealing sleeve.
• Carefully release and then slide the latch to insert it into the recesses marked with arrows.

12. Remove the door. Disconnect the electrical connector.




13. Remove the front seats. For more information refer to Front Seat (78.10.44/99)

14. Release the gear selector lever cable.

• Remove the clamp.
• Release the rope.

15. Remove the gear selector lever. Turn out 4 bolts.



16. Disconnect an intermediate shaft of a steering column from a steering column.

• Note the position in which the parts are installed.
• Unscrew the special bolt and discard the nut.

17. Disconnect 2 drainage tubes from the heater body.



18. Take the central air ducts of the heater to the side to gain access.



19. Turn out 2 bolts with a Torx head from the central arm of the panel of devices.




20. Remove the central speaker grille from the instrument panel. Release 4 clips.



21. Turn out a bolt of fastening of the top part of the panel of devices to a body.



22. Remove the mixing chamber panel. For more information, refer to Collection Chamber (80.15.62)

23. Turn out a bolt with a Torx head of fastening of an arm on the panel of devices to a body.



24.

CAUTION: Before disconnecting or removing components, clean the area around the contact surfaces and connections. Plug all open connections to avoid contamination of the system.

Disconnect 2 heater hoses from bulkhead. Release 2 clips.



25. Disconnect 2 pipelines of the conditioner from a body. Loosen the nut.

26.

ATTENTION: Immediately close the pipelines of the air conditioner with plugs to prevent dust and moisture from entering them.

Disconnect the 2 A/C pipes from the bulkhead.

• Turn out a bolt.
• Remove and discard o-rings.

27. Remove 2 adapter panels. Loosen 4 nuts.



28. Disconnect the 3 cables connecting to "mass" from the bottom of the A-pillar on the driver's side. Loosen 2 nuts.



29. Disconnect the 5 electrical connectors on the bottom of the A-pillar on the driver's side.



30. Disconnect 3 cables connecting to "mass" from the bottom of the A-pillar on the passenger side. Loosen 2 nuts.



31. Disconnect the 5 electrical connectors at the bottom of the A-pillar on the passenger side.

32. Disconnect an electric socket of the electric motor of a heater.



33. Disconnect 2 electrical connectors of the central distribution block (CJB).



34. Disconnect 2 electric sockets from the central strengthening of the panel of devices.

35. Disconnect fiber-optic cables from the central strengthening of the panel of devices. if the car is equipped with them. Disconnect the electrical connector.



36. Driver's side: Remove the Torx head bolt securing the heater housing to the bulkhead.

37. On the passenger side, remove the Torx head bolt securing the heater housing to the bulkhead.



38. With assistance, remove the instrument panel. Remove 4 Torx head screws.

Installation

1. With assistance, install the instrument panel. Tighten Torx Head Bolts (tightening torque 25 Nm).

2. On the passenger side, install the Torx head bolt securing the heater housing to the bulkhead and tighten (tightening torque 6 Nm).

3. Driver's side: Install the Torx head bolt securing the heater housing to the bulkhead and tighten (tightening torque 6 Nm).

4. Connect the fiber optic cables to the central reinforcement of the instrument panel.

5. Connect electric sockets to the central strengthening of the panel of devices.

6. Connect the electrical connectors of the central distribution block (CJB).

7. Connect an electric socket of the electric motor of a heater.

8. Connect electric sockets on the lower part of a forward rack of a body from outside the passenger.

9. Connect the connection cables with "weight " to the bottom of the A-pillar on the passenger side. Tighten nuts (tightening torque 10 Nm).

10. Connect electric sockets on the lower part of a forward rack of a body from outside the driver.

11. Connect the connection cables with "weight " to the bottom of the A-pillar on the driver's side. Tighten nuts (tightening torque 10 Nm).

12. Install adapter panels. Tighten nuts (tightening torque 10 Nm).

13. Connect the air conditioning pipes to the bulkhead.

• Clear the details.
• Install new o-rings.
• tighten bolt (tightening torque 10 Nm).

14. Connect pipelines of central air to a body. Tighten nuts (tightening torque 10 Nm).

15. Connect the heater hoses to the bulkhead.

16. Screw in the Torx bolt securing the instrument panel to the bulkhead and tighten it (tightening torque 25 Nm).

17. Install the mixing chamber panel. For more information, refer to Storage Chamber (80.15.62)

18. Screw a bolt of fastening of the top part of the panel of devices to a body and tighten (tightening torque 10 Nm).

19. Install the speaker grille. Engage clamps.

20. Screw in bolts with head Torx of the central bracket of the instrument panel and tighten (tightening torque 25 Nm).

21. Install the central air ducts of the heater.

22. Connect the drain pipes to the heater body.

23. Establish an intermediate shaft of a steering column. Screw in the special bolt and tighten the new nut (tightening torque 22 Nm).

24. Install the gear selector lever. Tighten the bolts (tightening torque 10 Nm).

25. Connect a cable of the lever of the selector of a transmission. Install the clamp.

26. Install the front seats. For more information refer to Front Seat (78.10.44/99)

27. With assistance, install the door assembly.

• Connect the electrical connector.
• Fasten the electrical connector.
• Fasten the sealing sleeve.
• Tighten the bolts (tightening torque 10 Nm).

28. Connect the door opening limiter to the A-pillar. Tighten Torx Head Bolts (tightening torque 10 Nm).

29. Establish the decorative panel from outside the driver.

• Connect the electrical connector.
• Engage clamp.
• Tighten the screws.

30. Establish the decorative panel from outside the passenger.

• Connect the electrical connector.
• Engage clamp.
• Tighten the screws.

31. Install doorway trim panels. For more information refer to Front Doorway Trim Panel (76.13.27)

32. Install the floor console. For more information refer to Floor Console (76.25.01)

33. Fill the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

34. Fill the air conditioning system. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)

35. Install the engine cover. For more information refer to Engine Cover - 4.4L (12.30.50)