INSTRUMENT PANEL ASSEMBLY

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position.

1. Disconnect and isolate the battery negative cable.
2. Remove the trim from the right and left A-pillars. (Refer to Trim Panel).
3. Remove the top cover.

Fig. 23

1. Remove the four nuts that secure the instrument panel to the studs on the dash panel near the windshield fence line (Fig. 23).
2. Remove the scuff plates from the right and left front door sills.
3. Remove the trim panels from the right and left inner cowl sides.
4. Remove the console from the floor panel transmission tunnel.
5. Remove the fuse cover from the junction block (JB).
6. Remove the cluster bezel.
7. Remove the steering column opening cover.
8. Remove the steering column bracket from the instrument panel steering column support bracket.

Fig. 24

1. Remove the screw that secures the lower tilting steering column shroud to the steering column multi-function switch mounting housing (Fig. 24).
2. Unsnap the two halves of the tilting steering column shroud from each other and remove both halves from the steering column.

Fig. 25

1. Disconnect the instrument panel wire harness connectors from the following steering column components (Fig. 25):

• • the two lower clockspring connector receptacles
  • the left multi-function switch connector receptacle
  • the right multi-function switch connector receptacle
  • the two ignition switch connector receptacles - the shifter interlock solenoid connector receptacle
  • if equipped, the sentry key immobilizer module (SKIM) connector receptacle.

1. Turn the ignition switch to the On position, then release and remove the shifter interlock cable connector from the ignition lock housing receptacle.
2. Turn the ignition switch back to the Lock position to prevent steering wheel rotation and the loss of clockspring centering following steering column removal.

Fig. 26

1. Remove the bolt that secures the coupler to the lower steering column shaft (Fig. 26).
2. Remove the four nuts that secure the steering column to the studs on the instrument panel steering column support bracket.
3. Remove the steering column from the instrument panel. Be certain that the steering wheel is locked and secured from rotation to prevent the loss of clockspring centering.

Fig. 27

1. Disconnect the left and right body wire harness connectors, the ignition off draw (IOD) wire harness connector and the fused B(+) wire harness connector from the connector receptacles of the JB (Fig. 27).

Fig. 28

1. Disconnect the instrument panel wire harness connectors from the following floor panel transmission tunnel components (Fig. 28): - the airbag control module (ACM) connector receptacle - the park brake switch terminal - the transmission shifter connector receptacle.
2. Remove the two nuts that secure the instrument panel wire harness ground eyelets to the studs on the floor panel transmission tunnel in front of and behind the ACM.
3. Disengage the retainers that secure the instrument panel wire harness to the floor panel transmission tunnel.
4. Remove the instrument panel to center floor tunnel bracket from the instrument panel and the floor panel transmission tunnel.
5. Remove the one screw that secures the floor duct to the heater and air conditioner housing near the driver side of the floor panel transmission tunnel and remove the duct from the housing.
6. If the vehicle is equipped with the manual heating and air conditioning system, disconnect the vacuum harness connector located near the driver side of the floor panel transmission tunnel behind the driver side floor duct.

Fig. 29

1. Remove the one screw that secures the instrument panel steering column support bracket to the driver side end of the heater and air conditioner housing (Fig. 29).

Fig. 30

1. Remove the one screw that secures the instrument panel steering column support bracket to the intermediate bracket on the driver side dash panel (Fig. 30).

Fig. 31

1. Remove the nut that secures the instrument panel steering column support bracket to the stud on the driver side cowl plenum panel (Fig. 31).

Fig. 32

1. Remove the nut and disconnect the safety strap from the support bracket. (Fig. 32)

Fig. 33

1. Remove the two screws that secure the instrument panel to the driver side cowl side inner panel (Fig. 33).
2. Remove the end cap.
3. Remove the lower right center bezel.
4. Remove the glove box.

Fig. 34

1. Disconnect the instrument panel wire harness connector from the lower cavity of the inline connector on the passenger side cowl side inner panel (Fig. 34).
2. Disconnect the two halves of the radio antenna coaxial cable connector near the right cowl side inner panel under the end of the instrument panel.

Fig. 35

1. Disconnect the two instrument panel wire harness connectors from the two heater and air conditioner housing connectors located near the blower motor on the passenger side end of the housing (Fig. 35).

Fig. 36

1. Remove the two screws that secure the passenger side instrument panel structural duct to the heater and air conditioner housing (Fig. 36).

Fig. 37

1. Remove the two screws that secure the instrument panel to the passenger side cowl side inner panel (Fig. 37).

Fig. 38

1. Depress the tab on the passenger side and with the aid of an assistant, lift the instrument panel assembly upward off of the studs on the dash panel near the windshield fence line and pull the instrument panel rearward from the dash panel and the cowl side inner panels and remove it through the driver side front door of the vehicle. (Fig. 38)

INSTALLATION

WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Prior to installing the instrument panel into the vehicle, loosen the three nuts that secure the instrument panel intermediate bracket and the accel-erator pedal assembly to the studs on the dash panel (Fig. 30).

Fig. 24

1. With the aid of an assistant, load the instrument panel assembly through the driver side front door of the vehicle and hang it on the studs on the dash panel near the windshield fence line (Fig. 23).
2. Be certain that the molded plastic guide/pin formations on the instrument panel structural duct are inserted into and seated in the guide holes at each cowl side inner panel.
3. Loosely install the two screws that secure each end of the instrument panel to the cowl side inner panels.
4. Install the two screws that secure the passenger side instrument panel structural duct to the heater and air conditioner housing (Fig. 36), and tighten to 11 N.m (8 ft. lbs.) .
5. Install the one screw that secures the instrument panel steering column support bracket to the driver side end of the heater and air conditioner housing (Fig. 29), and tighten the to 11 N.m (8 ft. lbs.) .
6. Tighten the two screws that secure each end of the instrument panel to the cowl side inner panels (Fig. 33) and (Fig. 37), to 11 N.m (8 ft. lbs.) .
7. Install the one screw that secures the instrument panel steering column support bracket to the intermediate bracket on the driver side dash panel (Fig. 30), and tighten to 11 Nm (8 ft. lbs.).
8. Tighten the three nuts that secure the instrument panel intermediate bracket and the accelerator pedal assembly to the studs on the dash panel to 11 Nm (8 ft. lbs.) .
9. Install the safety strap and tighten the nut.
10. Install the four nuts that secure the instrument panel to the studs on the dash panel near the windshield fence line and tighten to 11 N.m (8 ft. lbs.) .
11. Install the nut that secures the instrument panel steering column support bracket to the stud on the driver side cowl plenum panel (Fig. 31), and tighten to 28 N.m (21 ft. lbs.) .
12. Install the instrument panel to center floor tunnel bracket onto the instrument panel and the floor panel transmission tunnel.
13. Connect the two instrument panel wire harness connectors to the two heater and air conditioner housing connectors located near the blower motor on the passenger side end of the housing (Fig. 35).
14. Connect the two halves of the radio antenna coaxial cable connector near the passenger cowl side inner panel under the end of the instrument panel.
15. Connect the instrument panel wire harness connector to the lower cavity of the inline connector on the passenger side cowl side inner panel and tighten the connector screw (Fig. 34).
16. Install the lower right center bezel onto the instrument panel.
17. Install the end cap onto the instrument panel.
18. Install the glove box.
19. If equipped with the manual heating and air conditioning system, connect the vacuum harness connector located near the driver side of the floor panel transmission tunnel behind the driver side floor duct.
20. Position the driver side floor duct to the heater and air conditioner housing near the driver side of the floor panel transmission tunnel (Fig. 29).
21. Install the one screw that secures the driver side floor duct to the heater and air conditioner housing near the driver side of the floor panel transmission tunnel.
22. Route the instrument panel wire harness to the floor panel transmission tunnel and engage the retainers that secure the harness to the mounting brackets on the tunnel (Fig. 28).
23. Install the instrument panel wire harness ground eyelets to the studs on the floor panel transmission tunnel in front of and behind the airbag control module and secure the eyelets with nuts and tighten to 7 N.m (60 in. lbs.) .
24. Connect the instrument panel wire harness connectors to the following floor panel transmission tunnel components: - the airbag control module (ACM) connector receptacle - the park brake switch terminal - the transmission shifter connector receptacle.
25. Connect the left and right body wire harness connectors, the ignition off draw (IOD) wire harness connector and the fused B(+) wire harness connector to the connector receptacles of the junction block (JB) and tighten the connector screws (Fig. 27).
26. Engage the lower steering column shaft with the steering shaft coupler and position the steering column to the mounting studs on the instrument panel steering column support bracket (Fig. 26).
27. Install the four nuts that secure the steering column to the studs on the instrument panel steering column support bracket and tighten to 11 N.m (8 ft. lbs.) .
28. Install the bolt that secures the coupler to the lower steering column shaft and tighten to 49 N.m (36 ft. lbs.) .
29. Turn the ignition switch to the On position, then install the shifter interlock cable connector into the ignition lock housing receptacle.
30. onnect the instrument panel wire harness connectors to the following steering column components (Fig. 25): - the two lower clockspring connector receptacles - the left multi-function switch connector receptacle - the right multi-function switch connector receptacle - the two ignition switch connector receptacles - the shifter interlock solenoid connector receptacle - if the vehicle is so equipped, the sentry key immobilizer module (SKIM) connector receptacle.
31. Position the lower tilting steering column shroud to the steering column multi-function switch mounting housing, then install and tighten the screw that secures the shroud to the housing (Fig. 24).
32. Position the upper tilting steering column shroud over the steering column. Align the upper and lower shrouds with each other and snap the two halves together.
33. Install the steering column bracket onto the instrument panel steering column support bracket.
34. Install the steering column opening cover.
35. Install the cluster bezel.
36. Install the fuse cover onto the JB.
37. Install the console onto the floor panel transmission tunnel.
38. Install the trim panels onto the right and left inner cowl sides.
39. Install the scuff plates onto the right and left front door sills.
40. Install the top cover.
41. Install the trim onto the right and left a-pillars.
42. Connect the battery negative cable.

REMOVAL
The HVAC housing assembly must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, evaporator coil, blend door(s), and each of the various mode doors.

WARNING:

• ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
• REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. See: Service Precautions

1. Disconnect and isolate the battery negative cable.
2. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair\Procedures\Instrument Panel Assembly Replacement
3. Recover the refrigerant from the refrigerant system. See: Refrigerant\Service and Repair
4. Disconnect the liquid line refrigerant line from the evaporator inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. See: Hose/Line HVAC\Service and Repair
5. Disconnect the suction line refrigerant line from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. See: Hose/Line HVAC\Service and Repair
6. Disconnect the heater hoses from the heater core tubes. Clamp off the heater hoses to prevent loss of coolant. Install plugs in, or tape over the opened heater core tubes.
7. If the vehicle is equipped with the manual temperature control system, unplug the HVAC system vacuum supply line connector from the tee fitting near the heater core tubes.
8. Remove the coolant reserve/overflow bottle from the passenger side inner fender shield. See: Engine, Cooling and Exhaust\Cooling System\Coolant Reservoir
9. Remove the Powertrain Control Module (PCM) from the passenger side dash panel in the engine compartment and set it aside. Do not unplug the PCM wire harness connectors. See: Powertrain Management\Computers and Control Systems\Engine Control Module\Service and Repair

Fig.9 HVAC Housing - (rear view)

1. Remove the nuts from the HVAC housing mounting studs on the engine compartment side of the dash panel.

Fig.10 Rear Floor Ducts

1. Remove the rear floor heat ducts from the floor heat duct outlets.
2. Unplug the HVAC housing wire harness connectors.

Fig.11 Passenger Side Instrument Panel To Heater - A/C Housing Mounting

1. Remove the HVAC housing mounting nuts from the studs on the passenger compartment side of the dash panel.
2. Remove the HVAC housing from the vehicle, ensuring that the interior is covered in case of loss of fluids.

INSTALLATION

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. See: Service Precautions

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

1. Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
2. Install the HVAC housing mounting nuts to the studs on the passenger compartment side of the dash panel. Tighten the nuts to 4.5 Nm (40 in. lbs.) .
3. Connect the HVAC housing wire harness connectors.
4. Reinstall the rear floor heat ducts to the center floor heat duct outlets.
5. Install and tighten the nuts onto the HVAC housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 Nm (60 in. lbs.) .
6. Reinstall the PCM to the passenger side dash panel in the engine compartment. See: Powertrain Management\Computers and Control Systems\Engine Control Module\Service and Repair
7. Reinstall the coolant reserve/overflow bottle to the passenger side inner fender shield. See: Engine, Cooling and Exhaust\Cooling System\Coolant Reservoir
8. If the vehicle is equipped with the manual temperature control system, connect the HVAC system vacuum supply line connector to the tee fitting near the heater core tubes.
9. Unclamp/unplug the heater core hoses and tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system. See: Engine, Cooling and Exhaust\Cooling System\Service and Repair
10. Unplug or remove the tape from the suction line and the evaporator outlet tube fittings. Connect the suction line to the evaporator outlet tube. Tighten retaining nut to 28 Nm (250 in. lbs.) .
11. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line to the evaporator inlet tube. Tighten retaining nut to 28 Nm (250 in. lbs.) .
12. Evacuate the refrigerant system. See: Refrigerant\Service and Repair
13. Charge the refrigerant system. See: Refrigerant\Service and Repair
14. Install the instrument panel in the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair\Procedures\Instrument Panel Assembly Replacement
15. Connect the battery negative cable.
16. Start the engine and check for proper operation of the heating and air conditioning systems.

DISASSEMBLY

1. Remove the HVAC housing from the vehicle. See: HVAC Housing Removal and Installation
2. Place the HVAC housing with the tubing side down on a work bench, making allowance for leakage of fluids.

Fig.12 Split Foam Seal At Panel Outlet

1. Using a sharp knife, split the foam seal surrounding the panel outlet opening, at the dividing line of the upper and lower cases.
2. Place the HVAC housing in the upright position on the work bench.

Fig.13 Mode Door Actuators - Manual System

Fig.14 Mode Door Actuator - AZC System

1. Remove the mode door actuator on the left side of the housing, which controls the mode door in the top of the case.

Fig.15 Remove Screw With Plastic Washer

1. Remove the screw with plastic washer holding the lever assembly to the upper case section, and move aside.

Fig.16 HVAC Housing Clips

1. Remove the 5 clips that secure the two housing halves to each other. There are 2 on either side at the center, and 1 located at the forward end of the mode door side of the case.

Fig.17 Wire Harness Electrical Connector(s)

1. Release the wire harness electrical connector(s) from the mounts on the lower case at the blower motor end of the unit.
2. Remove the 10 screws that secure the two housing halves to each other.

Fig.18 HVAC Housing-Case Seperated

1. Separate the top half of the HVAC housing from the bottom half.

Fig.19 Blend Door Sub-Assembly (AZC)

1. Place the top half of the HVAC housing on the bottom half. Be certain that each of the door pivot pins align with the pivot holes in the HVAC housing.
2. Install the 10 screws that secure the two housing halves to each other. Tighten the HVAC housing screws to 2.2 Nm (20 in. lbs.) .
3. Attach the wire harness electrical connector(s) to the mounts on the lower case at the blower motor end of the unit.
4. Install the 5 clips that secure the two housing halves to each other. Check doors for binding after replacement, and after assembly of housing.
5. Install the screw with plastic washer holding the lever assembly to the upper case section.
6. Install the mode door actuator on the left side of the housing.