Dash Removal & Defroster Flap Replacement Information
DASH REMOVAL:1. Disconnect the battery negative cable.
2. Remove the instrument pack.
3. Remove the left window defroster vent cover by removing the lower nut, carefully prying out the top and sliding the panel down.
4. Remove the right A post kick panel.
5. Remove the right dash liner.
6. Remove the air discharge duct.
7. Remove the right window defroster vent cover by removing the lower nut, carefully prying out the top, and sliding the panel down.
8. Open the glove box door and carefully pry off the center dashboard wood panel. Remove the center vent.
9. Remove the two screws behind the center vent.
10. Remove the two nuts from the support brackets on either side of the center console.
11. At the outside of the dash, remove the upper bolts from the support brackets. Loosen the lower bolts and move the brackets down.
12. Remove the four mounting screws and disconnect the three electrical connectors (1 brown, 1 green, 1 black PMHD). Remove the lighting logic unit and trip computer assembly.
13. Remove the bolt located behind the instrument pack.
14. Remove the bolts on the left and right side of the dash.
15. Remove the glove box rear panel and disconnect the in-car sensor (JST connector). Disconnect the aspirator tube.
16. Disconnect the solar sensor connector below the dash in the glove box area (JST connector).
17. Loosen the two lower screws and remove the two upper screws from the electrical component panel. Lower the panel.
18. Disconnect the yellow , black, and green vacuum lines at the right of the climate control unit. (Yellow connects to red.)
19. Disconnect the glove box light connector at the right of the climate control unit (black PMHD).
20. Carefully remove the dash assembly to the right to clear the steering wheel.
DEFROSTER FLAP REPLACEMENT:
1. Note position first, then carefully pry up the solar sensor panel. Disconnect the JST connector and remove the solar sensor assembly.
2. Remove the center screw, lift the vent at the screw, and slide it toward the opposite side of the car for removal. Repeat for the other vent.
3. Note the position of the middle retaining clip and remove the screw and clip. Repeat for the other vent.
4. Remove the three remaining screws from each vent and allow the defroster flap assemblies to drop into the dash. Disconnect the hoses from the vacuum actuators and remove the flap assemblies.
5. Prior to installing the revised flap assemblies, the main flap pivots and vacuum actuator pivot should be properly lubricated with "SUPER LUBE" to eliminate a possibility of flap "creak". (Super Lube is manufactured by SYNCO Chemical Corporation, Bohemia, New York 11716, and is readily available at most parts jobbers and can also be purchased through Jaguar Parts Department under Part No. JAG 135).
NOTE: Use of the wrong lubricant on plastic can cause damage to the flap assembly. Super lube is a teflon type lubricant which contains no petroleum distillates.
NOTE: Vehicles above VIN 527775 may have had the defrost flap vacuum circuit modified at production. To eliminate defroster flap "creak" the defroster solenoid blue vacuum restrictor Part No. JLM 750 was removed. If such a vehicle exhibits flap "banging", it will be necessary to simply add the blue restrictor, Part No. JLM 750, to the vacuum line, Fig. 1. At the same time the restrictor is added, it will be necessary to lubricate the pivot as detailed above to ensure no flap "creaking" results.
6. Replace the defroster flap assemblies with the revised units in the reverse order.
NOTE: Do not reinstall the dash assembly at this time.