Ford Fusion: Instrument Panel and Console / Instrument Panel. Removal and Installation

Special Tool(s) / General Equipment

Removal

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

All vehicles

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1.   WARNING: Turn the ignition OFF and wait one minute to deplete the backup power supply. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment.

   If a SRS fault is present, continue to Step 3. Otherwise, turn the ignition off, wait at least one minute and continue to Step 4.
   

1. Depower the SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
   

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

Vehicles equipped with the 2.7L engine

1. Remove the air cleaner.
   Refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

All vehicles

1. NOTE: If equipped.

   Remove the bolts and position the cabin heater aside.
   Torque: 53 lb.in (6 Nm)

1. NOTE: Make sure all openings are sealed.

   Remove the evaporator pipe nut, position the flange and pipe aside.
   Torque: 97 lb.in (11 Nm)

1. 
   
   

     WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth.

   Release the cooling system pressure by slowly turning the degas bottle cap between 2 and 3 turns and remove the degas bottle cap.
   

1. NOTE: Be prepared to collect escaping fluid.

   Install hose clamping pliers on the coolant hoses, release the hose clamps and disconnect the coolant hoses.
   Use the General Equipment: Hose Clamp(s)

1. On both sides, remove the front door.
   Refer to: Front Door (501-03 Body Closures, Removal and Installation).
   

Police vehicles

1. Remove the bolts, nuts, release the harenss retainers and remove the plate.
   Torque: 55 lb.in (6.2 Nm)

1. 
   Release the clips and remove the LH lower trim panel.
   
   • Disconnect the electrical connectors.
     Use the General Equipment: Interior Trim Remover

1. Release the clips and remove the RH lower trim panel.
   Use the General Equipment: Interior Trim Remover

1. Release the clips and remove the center lower trim panel.
   

1. Release the clips and remove the center stack trim panel..
   Use the General Equipment: Interior Trim Remover

1. 
   Release the clips and remove the selector trim panel.
   
   • Disconnect the electrical connectors.
     

1. 
   Remove bolts, disconnect the electrical connectrs, release the harness retainers and remove the selector mounting bracket.
   
   1. Remove the bolts.
      Torque: 55 lb.in (6.2 Nm)
   2. Remove the bolts.
      Torque: 18 lb.in (2.05 Nm)

1. Remove the bolts, detach the harness push pins, bracket push pins and remove the bracket.
   

All vehicles except police

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

1. If equipped, remove the selector lever assembly.
   

1. If equipped, remove the gearshift lever.
   

All vehicles

1. On both sides.
   Position the front door weatherstrip aside.
   

1. On both sides.
   Release the clips and remove the instrument panel side trim panel.
   Use the General Equipment: Interior Trim Remover

1. On both sides.
   Remove the cowl side trim panel.
   Use the General Equipment: Interior Trim Remover

1. On both sides.
   Release the clips and remove the scuff plate.
   Use the General Equipment: Interior Trim Remover

1. On both sides.
   Release the clips and remove the lower cowl trim panel.
   Use the General Equipment: Interior Trim Remover

1. On both sides, remove the A-pillar trim panel.
   Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
   

1. Remove the push pins and RH insulator panel.
   

1. NOTICE: Do not allow the steering wheel to rotate while the steering shaft is disconnect, or damage to the clockspring may result.

   Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering column shaft from the steering gear.
   Torque: 21 lb.ft (28 Nm)

1. Position the RH carpet aside.
   

1. Remove the hood latch release handle.
   Refer to: Hood Latch Release Handle (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
   

1. Remove the push pins and position the LH carpet aside.
   

1. Remove the bolt and the HVAC duct.
   

1. Remove the HVAC duct.
   

1. Remove the bolts and the instrument panel center brace.
   Torque: 133 lb.in (15 Nm)

1.   WARNING: Turn the ignition OFF and wait one minute to deplete the backup power supply. Ignition must remain OFF until repair is complete. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment.

   • Turn the ignition off, wait at least one minute.
     
   • Disconnect the electrical connector.
     

1. Disconnect the electrical connectors.
   

1. Disconnect the electrical connectors and position the wiring tray aside.
   

1. Release the clips and position aside the instrument panel finish panel.
   

1. Through the opening disconnect the BCM eletrical connectors.
   

1. NOTE: LH side of instrument panel.

   Disconnect the BCM electrical connectors.
   

1. NOTE: RH side of instrument panel.

   Disconnect the electrical connector.
   

1. NOTE: If equipped.

   Disconnect the electrical connectors and release the wiring harness retainer. Release the tabs and remove the APIM.
   

1. Remove the cowl panel grille.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

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

1. On both sides.
   Remove the A-pillar to in-vehicle cross beam support bolt cover.
   Use the General Equipment: Interior Trim Remover

1. On both sides.
   Remove the A-pillar to in-vehicle cross beam support bolt.
   Torque: 26 lb.ft (35 Nm)

1. Remove the HVAC nut.
   Torque: 133 lb.in (15 Nm)

1. On both sides.
   Remove the instrument panel support bolts.
   Torque: 17 lb.ft (22.5 Nm)

1. 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.

   Rotate the instrument panel face down and remove through the LH front door opening.
   

Installation

1. To install, reverse the removal procedure.
   

1. If SRS was depowered, repower SRS.
   Refer to: Supplemental Restraint System (SRS) Depowering and Repowering (501-20B Supplemental Restraint System, General Procedures).
   

1. Fill and bleed the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 2.7L EcoBoost (238kW/324PS), General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling - 2.5L Duratec (125kW/170PS), General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 2.0L EcoBoost (184kW/250PS) – MI4, General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 2.7L EcoBoost (238kW/324PS), General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 2.0L EcoBoost (184kW/250PS) – MI4, General Procedures).
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling - 2.5L Duratec (125kW/170PS), General Procedures).