INSTRUMENT PANEL ASSEMBLY
REMOVAL
1. Disconnect the electrical connector (3) at the A-pillar cowl area and separate the check strap (2) from the footman's loop (1).
2. Open the doors past 90° to aid in removal of the I/P assembly.
3. Disconnect and isolate battery negative cable.
4. Remove the center console, (Refer to 23 - BODY/INTERIOR/CENTER CONSOLE - REMOVAL).
5. Disconnect the center I/P wire harness electrical connectors (1, 2 and 3).
6. Release the push pin hangers (2) and position aside the harness (1).
7. Using a trim stick C-4755 or equivalent, release the tabs and separate the lower steering column opening cover (1).
8. Using a trim stick C-4755 or equivalent, release the upper clips (1) and rotate the steering column opening cover (3) down and remove from lower tabs (2).
9. Remove the bolts (1) and remove the reinforcement plate (2).
10. Remove the amplifier, (Refer to 8 - ELECTRICAL/AUDIO/AMPLIFIER - REMOVAL).
11. Remove the steering column as necessary, (Refer to 19 - STEERING/COLUMN - REMOVAL).
12. Using a trim stick C-4755 or equivalent, remove the end caps (1).
13. On automatic transmission vehicles, remove the shifter, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 45RFE/545RFE/SHIFT MECHANISM - REMOVAL).
14. Remove the transfercase shifter, (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER CASE/SHIFT LEVER - REMOVAL).
15. Using a trim stick C-4755 or equivalent, release the clips (2) and rotate the lower center trim (3) down and release the tabs (1).
16. Using a trim stick C-4755 or equivalent (2), release the clips in the rear of the upper trim (1).
17. Rotate the upper trim (2) back and release the front (1).
18. Disconnect the electrical connector (4) and remove the upper center cover (1).
19. Remove the screws (2) and using a trim stick C-4755 or equivalent, separate the center bezel (1).
20. Disconnect the HVAC control cables (1 and 9) and disconnect the electrical connectors (3).
21. Remove the radio, (Refer to 8 - ELECTRICAL/AUDIO/RADIO - REMOVAL).
22. Remove the screws (2) and remove the center I/P trim panels (1 and 3).
23. Remove the nuts (2) and bolts (1) and remove the center support brackets (4).
24. Remove the clutch pedal clip and separate the clutch pedal rod, if equipped.
25. Remove the brake pedal clip (2) and separate the brake pedal rod (1).
26. Remove the nuts and separate the grounds (2).
27. Disconnect the driver's side electrical connectors.
28. Disconnect the passenger side electrical connectors (1 and 2).
29. Disconnect the antenna connector (1).
30. Remove the glove box (1).
31. Drain the refrigerant, (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
32. Drain the coolant, (Refer to 7 - COOLING - STANDARD PROCEDURE).
33. Remove the EGR tube (1), (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - REMOVAL).
34. Using cable-type spring clamp pliers or equivalent, release the hose clamps that secure the heater hoses (2) to the heater core tubes (1) and disconnect the hoses from the tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during HVAC housing assembly removal.
35. Remove the nut (2) that secures the A/C liquid line (3) and A/C suction line (5) to the A/C expansion valve (1).
36. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-ring seals.
37. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports.
38. Position aside the harness at the brake booster.
39. Remove the brake booster bracket nuts (2).
40. Disconnect the positive battery cable.
41. Remove the right side ground.
42. Position aside the power steering reservoir.
43. Remove the battery tray, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
44. Release the wire harness grommet (2) and separate any remaining support clips for the wires harness (1).
45. Remove the trim caps (2) and remove the fenceline nuts (3).
46. Remove the side support bolts (1) and position the I/P assembly back.
47. Pull the main wire harness (2) from the hole in the cowl (1).
48. Remove the I/P from the vehicle.
INSTALLATION
1. Position the I/P assembly into the vehicle and support back.
2. Position the wire harness (2) through the cowl panel (1) and seat the grommet (3) fully.
3. Loosely install the nuts (3) onto the fenceline studs (1).
4. Position the I/P assembly (4) back and carefully push the heater core and A/C lines and the brake booster support studs, through the cowl.
5. Position the I/P over the fenceline studs (1).
6. Loosely install the side support bolts (1).
7. Install the center support brackets (4) over the studs (3) and install the bolts (1) and nuts (2).
8. Tighten the side support bolts to 11 N·m (8 ft. lbs.).
9. Tighten the fenceline nuts to 12 N·m (9 ft. lbs.).
10. Tighten the bolts (1) and nuts (2) to 8 N·m (6 ft. lbs.).
11. Position the main wire harness (1) back into place and seat all the support clips fully.
12. Install the battery tray, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - INSTALLATION).
13. Position the power steering reservoir back into place.
14. Install the right side grounds (2) and install the nuts (3).
15. Connect the positive battery cable (4).
16. Install the brake booster bracket nuts (2) and tighten to 18 N·m (13.5 ft. lbs.).
17. Position the wire harness back and secure the support clips fully.
18. Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve ports.
19. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
20. Connect the A/C liquid line (3) and A/C suction line (5) onto the A/C expansion valve (1).
21. Install the nut (2) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 23 N·m (17 ft. lbs.).
22. Remove the previously installed plugs or caps and connect the heater hoses (2) to the heater core tubes (1).
23. Using cable-type spring clamp pliers or equivalent, correctly position the two hose clamps that secure the heater hoses to the heater core tubes and engage the clamps to the tubes.
24. Install the EGR tube (1), (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - INSTALLATION).
25. Fill the coolant, (Refer to 7 - COOLING - STANDARD PROCEDURE).
26. Evacuate the A/C system, (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
27. Install the glove box (1), (Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE BOX - INSTALLATION).
28. Connect the antenna connector (1).
29. Connect the electrical connectors (1 and 2).
30. Connect the grounds (2) and install the nuts.
31. Install the nut to the lower HVAC support bracket under the glove box.
32. Connect the brake pedal rod (1) and install the clip (2).
33. If equipped, connect the clutch pedal rod and install the clip.
34. Install the center I/P trim panels (1 and 3) and install the screws (2).
35. Install the radio, (Refer to 8 - ELECTRICAL/AUDIO/RADIO - INSTALLATION).
36. Connect the HVAC control cables (1 and 9) and connect the electrical connectors (3 and 4).
37. Position the center bezel (1) onto the I/P and seat the clips fully.
38. Install the lower screws (2).
39. Connect the electrical connector (4) and position the upper center cover onto the top of the I/P.
40. Position the front of the cover (1) onto the center support and rotate the trim (2) back and seat the clips fully.
41. Position the lower tabs (1) into the slots and rotate the trim (3) up and seat the clips (2) fully.
42. Install the transfercase shifter, (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER CASE/SHIFT LEVER - INSTALLATION).
43. Install the automatic transmission shifter, if equipped, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 45RFE/545RFE/SHIFT MECHANISM - INSTALLATION).
44. Position the end caps (1) onto the I/P and seat fully.
45. Install the steering column, (Refer to 19 - STEERING/COLUMN - INSTALLATION).
46. Install the amplifier, (Refer to 8 - ELECTRICAL/AUDIO/AMPLIFIER - INSTALLATION).
47. Install the reinforcement plate (2) and install the bolts (1).
48. Tighten the bolts (1) to 11 N·m (8 ft. lbs.).
49. Position the steering column opening cover (3) onto the lower tabs (2), rotate up and seat the clips (1) fully.
50. Position the lower opening trim onto the I/P and seat the clips (1) fully.
51. Position the center harness (1) back into place and seat the support clips (2) fully.
52. Connect the center harness electrical connectors (1, 2 and 3).
53. Install the center console, (Refer to 23 - BODY/INTERIOR/CENTER CONSOLE - INSTALLATION).
54. Install the center console, (Refer to 23 - BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)
55. Connect the battery cables (4).
56. Secure the front door check straps (2) over the footman's loop (1) and connect the electrical connector (3).