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into the keyhole slots.
(3) Install the lower two bolts. (4) Tighten the regulator bolts to 10 N·m (89 in.
lbs.).
(5) Position the stabilizer,
install the nuts and
tighten to 10 N·m (89 in. lbs.).
(6) Using the window handle raise the regulator to
the position shown in (Fig. 14).
(7) Remove the glass support and connect to the
regulator lift plate.
(8) Install the glass nuts and tighten to 10 N·m
(9) Remove the window handle and install the
(89 in. lbs.).
waterdam.
DR WINDOW REGULATOR - MANUAL (Continued)
DOOR - FRONT
23 - 27
SIDE VIEW MIRROR FLAG REMOVAL
(1) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
CAUTION: Do not use a drill to remove the heat stakes.
(2) Remove the heat stakes using a razor knife or
equivalent.
(3) Release the tabs and remove the mirror flag.
INSTALLATION
NOTE: Clean the excess heat staking off of the studs to aid installation.
(1) Install the new mirror flag over the tabs and
install the screws into the heat stake studs.
(2) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
Fig.16WINDOWREGULATOR-MANUAL
1 - DOOR 2 - REGULATOR BOLTS (4) 3 - REGULATOR 4 - STABILIZER NUTS (2)
23 - 28
DOORS - REAR
DOORS - REAR
TABLE OF CONTENTS
page
DR
page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 28
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 32
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 33
EXTERIOR HANDLE
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33GLASS RUN CHANNEL
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34HINGE
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34INSIDE HANDLE ACTUATOR
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DOOR REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the b-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the outline of the door hinges on the door to aid in instal- lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be seperated from the hinge. the washers are removed the door may have to be re-adjusted.
If
(4) Remove the nuts and bolts attaching the door
hinges to the door.
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the bolts, nuts and washers, if there were removed previously, and tighten to 28 N·m (21
ft. lbs.).(3) Connect the electrical connector. (4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is recommended that you adjust the rear door before adjusting the front door. † Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels. † During adjustment procedures, is recom- mended that all the hinge fasteners be loosened except for the upper most fasteners. Adjustments can be made using the upper fasteners to hold the door with final torque of the fasteners occurring after correct door positioning is achieved.
it
DR DOOR (Continued)
DOORS - REAR
23 - 29
the hinge to door fasteners and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done correctly, the top of the door is positioned over flush to the roof. (Refer to 23 - BODY/BODY STRUC- TURE/GAP AND FLUSH - SPECIFICATIONS)
(1) Support the door with a suitable lifting device. (2) Remove the latch striker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRIKER - REMOVAL)
(3) Loosen the hinge to hinge pillar fasteners (Refer to 23 - BODY/DOORS - REAR/HINGE - REMOVAL) or loosen the hinge to door fasteners (Refer to 23 - BODY/DOORS - REAR/DOOR - REMOVAL).
(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten to hinge pillar fasteners or the door to hinges fasteners and fasteners to 28 N·m (21 ft. lbs.). (Refer to 23 - BODY/DOORS - REAR/HINGE - INSTALLATION)
(6) Install the latch striker. (Refer to 23 - BODY/ DOORS - REAR/LATCH STRIKER - INSTALLA- TION)
IN/OUT
NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one hinge at a time and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
(1) Support the door with a suitable lifting device. (2) Remove the latch striker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRIKER - REMOVAL)
(3) Loosen the hinge to door fasteners. (Refer to 23
- BODY/DOORS - REAR/DOOR - REMOVAL)
(4) Adjust the front of the door to the correct posi- tion. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the door to hinges fasteners to 28 N·m
(21 ft. lbs.).
(6) Install the latch striker. (Refer to 23 - BODY/ DOORS - REAR/LATCH STRIKER - INSTALLA- TION)
Fig.1DOORASSEMBLY
1 - NUTS (2) 2 - UPPER HINGE 3 - UPPER STUD 4 - REAR DOOR 5 - WIRE HARNESS 6 - LOWER STUD 7 - LOWER HINGE 8 - ELECTRICAL CONNECTOR 9 - BOLTS (2)
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge pillar fasteners one hinge at a time and moving the door to the cor- rect position.
(1) Support the door with a suitable lifting device. (2) Loosen the hinge to hinge pillar fasteners. (Refer to 23 - BODY/DOORS - REAR/HINGE - REMOVAL)
(3) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(4) Tighten to hinge pillar fasteners to 28 N·m (21
ft. lbs.). (Refer to 23 - BODY/DOORS - REAR/HINGE - INSTALLATION)NOTE: Use a suitable body sealer on the hinge to body mating surfaces.
UP/DOWN
NOTE: Up/down door adjustment is done by loosen- ing either the hinge to the hinge pillar fasteners or
23 - 30
DOORS - REAR
DOOR GLASS REMOVAL
DR
(1) Remove the glass run channels. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - REMOVAL)
(2) Remove the glass support and place the glass
into the bottom of the door.
(3) Separate the glass run weatherstrip from the
rear of the window opening.
(4) Remove the inner belt molding. (Refer to 23 - DOOR
BODY/WEATHERSTRIP/SEALS/FRONT INNER BELT WEATHERSTRIP - REMOVAL)
(5) Remove the glass from the window opening.
INSTALLATION
(1) Install the glass through the window opening
and pace the glass into the bottom of the door.
(2) Install the inner belt molding. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - INSTALLATION) (3) Stuff the glass run weatherstrip into the win-
dow frame.
(4) Secure the glass in the up position using a
wood wedge or equivalent.
(5) Install the glass run channels. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - INSTALLATION)
EXTERIOR HANDLE REMOVAL
(1) Remove the front glass run channel. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - REMOVAL)
(2) Disconnect the latch actuator rod. (Fig. 2) (3) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the latch and install the nuts. (2) Connect the latch actuator rod. (3) Install the front glass run channel. (Refer to 23
- BODY/DOORS - REAR/GLASS RUN CHANNEL - INSTALLATION)GLASS RUN CHANNEL REMOVAL
(1) Remove the window regulator. (Refer to 23 - BODY/DOORS - REAR/WINDOW REGULATOR - REMOVAL)
(2) Remove the bottom screws and loosen the top
screws from bolt channels. (Fig. 3) and (Fig. 4)
Fig.2EXTERIORHANDLE
1 - LATCH ACTUATOR ROD 2 - LATCH 3 - NUTS (2)
(3) Slide the channels up to disengage from the
keyhole slots.
(4) Separate the glass run weatherstrip from the
channel and remove the channels.
Fig.3FRONTRUNCHANNEL
1 - BOLTS 2 - FRONT RUN CHANNEL
DR GLASS RUN CHANNEL (Continued)
DOORS - REAR
23 - 31
UPPER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the nut and bolt attaching the hinge to
the door.
(3) Remove the three bolts attaching the hinge to
the b-pillar and remove the hinge.
LOWER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the lower b-pillar trim. (Refer to 23 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR REMOVAL)
(3) Remove the nut and bolt attaching the hinge to
the door.
the b-pillar.
(4) Remove the two bolts attaching the hinge to
(5) From the inside of the vehicle remove the remaining bolt attaching the hinge to the b-pillar and remove the hinge.
INSTALLATION
UPPER HINGE
(1) Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28
N·m (21 ft. lbs.).(2) Install the three hinge to b-pillar bolts and
tighten to 28 N·m (21 ft. lbs.).
(3) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
LOWER HINGE
(1) Install the hinge and install the b-pillar bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28
N·m (21 ft. lbs.).(4) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
(5) Install the lower b-pillar trim. (Refer to 23 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR INSTALLATION)
INSIDE HANDLE ACTUATOR REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 5)
(2) Remove the door trim panel. (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 6) (4) Remove the nuts and remove the remote han-
dle actuator.
Fig.4REARRUNCHANNEL
1 - REAR RUN CHANNEL 2 - SCREW LOCATIONS
INSTALLATION
(1) Position the run channels into the door and
engage the upper screws into the keyhole slots.
(2) Install the lower screws and tighten to 10 N·m
(89 in. lbs.).
lbs.).
nels.
(3) Tighten the upper screws to 10 N·m (89 in.
(4) Stuff the glass run weatherstrip into the chan-
(5) Verify correct window operation. (6) Install the window regulator. (Refer to 23 - BODY/DOORS - REAR/WINDOW REGULATOR - INSTALLATION)
HINGE REMOVAL
NOTE: It is not necessary to remove the door to replace the hinges if they are replaced one at a time.
NOTE: The epoxy coated washers should not be removed from the hinge. the washers are removed the door may have to be re-adjusted.
If
(1) Open the front door
DOORS - REAR
23 - 32
INSIDE HANDLE ACTUATOR (Continued)DR
LATCH REMOVAL
(1) Raise the window to the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Disconnect the actuator rods. (4) Remove the bolts. (Fig. 7) (5) Disconnect the electrical connector and remove
the latch.
Fig.5INSIDEHANDLEACTUATOR
1 - TRIM PANEL OPENING 2 - INSIDE LATCH HANDLE 3 - BOLT
Fig.6REMOTEHANDLEACTUATOR
1 - NUTS (2) 2 - LATCH ACTUATOR ROD 3 - HANDLE REMOTE
INSTALLATION
(1) Install the remote handle actuator and install
the nuts.
(2) Tighten the nuts to 10 N·m (89 in. lbs.). (3) Connect the latch actuator rod. (4) Install the door trim panel.
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - INSTALLA- TION)
(5) Install the inside handle and install the bolt. (6) Tighten the bolt to 9 N·m (80 in. lbs.).
Fig.7LATCHASSEMBLY
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - LATCH ASSEMBLY 4 - BOLTS
INSTALLATION
(1) Connect the electrical connector and install the
(2) Install the bolts and tighten to 10 N·m (89 in.
latch assembly.
lbs.).
(3) Connect the actuator rods. (4) Adjust the latch as needed.
(Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 8)
DR LATCH (Continued)
DOORS - REAR
23 - 33
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N·m (30 in.
lbs.).
(5) Test handle for proper operation.
TRIM PANEL REMOVAL
(1) Remove the window crank, if equipped. (Fig.
(2) Remove the interior handle.
(Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - REMOVAL)
(3) Remove the screw near the inside handle. (Fig.
10)
9)
CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur.
(4) Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly.
(5) Disconnect the power window switch electrical
connector, if equipped, and remove the trim panel.
Fig.9TRIMPANEL
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - ATTACHMENT HOOKS 4 - SCREW 5 - TRIM PANEL
INSTALLATION
(1) Position the trim panel onto the lower hooks and connect the power window switch electrical con- nector, if equipped.
(2) Position the remaining trim panel attachment hooks into the door panel and seat the trim panel into the belt seal fully.
(3) Install the screw near the inside handle. (4) Install
(Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
the interior handle.
(5) Install the window crank, if equipped.
Fig.8LATCHADJUSTMENTSCREW-TYPICAL
1 - DOOR LATCH 2 - MYLAR TAPE 3 - ADJUSTMENT SCREW
LATCH STRIKER REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the striker.
(2) Remove the bolts and remove the striker.
INSTALLATION
(1) Install the striker and install the bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Adjust the striker if needed.
(Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - ADJUST- MENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid in adjustment.
(2) Loosen the striker bolts. (3) Change the striker position to adjust the rear gap and flush measurement. (Refer to 23 - BODY/ BODY STRUCTURE/GAP AND FLUSH - SPECIFI- CATIONS)
(4) Tighten the bolts to 28 N·m (21 ft. lbs.).
DOORS - REAR
23 - 34
TRIM PANEL (Continued)DR
(5) Disengage the door glass from the regulator lift
plate and position into the full up position.
(6) Secure the glass in the up position using a
wood wedge or equivalent. (7) Lower the regulator. (8) Disconnect the electrical connector. (Fig. 12) (9) Remove the lower regulator bolt and loosen the
upper two. (Fig. 12)
slots in the door panel.
inner door panel.
(10) Slide the regulator up and out of the keyhole
(11) Remove the regulator through the hole in the
Fig.10WINDOWCRANKREMOVALTOOL
1 - WINDOW CRANK REMOVAL TOOL 2 - WINDOW CRANK
WATERDAM REMOVAL
(1) Remove the inside handle actuator. (Refer to 23
- BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - REMOVAL)(2) Remove the speaker. (Refer to 8 - ELECTRI-
CAL/AUDIO/SPEAKER - REMOVAL)
(3) Separate the waterdam from the inner door
panel and off of the latch linkages.
INSTALLATION
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Secure the waterdam to the inner door panel. (3) Install the speaker. (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION)
(4) Install the inside handle actuator. (Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
WINDOW REGULATOR - POWER REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Remove the window switch from the door trim
panel and reconnect it to the door wire harness.
(3) Raise the window to the position shown and remove the two nuts attaching the glass to the win- dow regulator. (Fig. 11)
(4) Remove the stabilizer nut.
Fig.11GLASSPOSITIONING
1 - SIGHT WINDOW 2 - STABILIZER NUT 3 - GLASS LIFT PLATE
INSTALLATION
(1) Install the regulator through the hole in the
inner door panel.
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the lower regulator bolt and tighten all
three to 10 N·m (89 in. lbs.).
(4) Connect the electrical connector. (5) Position the stabilizer, install tighten to 10 N·m (89 in. lbs.).
the nut and
(6) Raise the regulator to the position shown in
(Fig. 11).
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(7) Remove the glass support and connect to the
(8) Install the glass nuts and tighten to 10 N·m
(9) Disconnect the window switch and install into
(10) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
DR WINDOW REGULATOR - POWER (Continued)
DOORS - REAR
23 - 35
Fig.12WINDOWREGULATORMOTOR
Fig.13WINDOWREGULATOR-MANUAL
1 - REGULATOR BOLTS 2 - REGULATOR MOTOR 3 - ELECTRICAL CONNECTOR.
WINDOW REGULATOR - MANUAL REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Reinstall the window handle and raise the win- dow to the position shown and remove the nuts. (Fig. 11)
(3) Remove the stabilizer nuts. (Fig. 13) (4) Disengage the door glass from the regulator lift
plate and position into the full up position.
(5) Secure the glass in the up position using a
wood wedge or equivalent. (6) Lower the regulator. (7) Remove the two back regulator bolts and
loosen the front two.
slots in the door panel.
inner door panel.
(8) Slide the regulator up and out of the keyhole
(9) Remove the regulator through the hole in the
1 - DOOR 2 - REGULATOR BOLTS (4) 3 - STABILIZER NUTS (2) 4 - REGULATOR
INSTALLATION
inner door panel.
(1) Install the regulator through the hole in the
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the back regulator bolts and tighten all
four to 10 N·m (89 in. lbs.).
(4) Position the stabilizer,
install the nuts and
tighten to 10 N·m (89 in. lbs.).
(5) Using the window handle raise the regulator to
the position shown in (Fig. 11).
(6) Remove the glass support and connect to the
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(7) Install the glass nuts and tighten to 10 N·m
(8) Disconnect the window switch and install into
(9) Using the window handle raise the regulator to the position shown in (Refer to 23 - BODY/DOORS - REAR/WATERDAM - INSTALLATION)
23 - 36
EXTERIOR
EXTERIOR
TABLE OF CONTENTS
page
DR
page
BODY SIDE MOLDINGS
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40BODY ISOLATORS
GRILLE FRAME
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40CARGO BOX
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41CARGO BOX - TIE DOWN
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41COWL GRILLE
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41EXTERIOR NAME PLATES
UPPER RADIATOR CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42FRONT FENDER
SIDE VIEW MIRROR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44FUEL FILL DOOR
REAR FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44BODY SIDE MOLDINGS REMOVAL
NOTE: Body side moldings are attached to the body panels with adhesive tape.
(2) Wipe area with a clean lint free cloth moist- ened with a 50% solution of water and alcohol and wipe dry immediately with a dry lint free cloth.
(3) Apply new body side molding using the guide tape on the body panel and apply consistent and uni- form pressure of approximately 40 p.s.i. over the entire surface of the molding.
(1) Apply a length of masking tape on the body panel, parallel to the top edge of the molding and to one end to use as a guide for installation, if neces- sary.
(2) If
temperature is below 21°C (70°F) warm molding with a heat lamp or gun. Do not exceed 52°C (120°F) when heating molding.
(3) Using a trim stick C-4755 or equivalent, remove and discard the molding from the outside of the body panel.
INSTALLATION
(1) Thoroughly clean all residue from the body side
molding attachment area of the body panel.
BODY ISOLATORS REMOVAL
(1) Loosen all cab to frame mounting bolts (six
standard cab, eight quad cab). (Fig. 1)
(2) Remove the mounting bolts and rebound cush-
ions
(3) Using a floor jack and block of wood under the cab sill, lift the body to gain access to the isolators.
(4) Remove the isolators. (5) Install new isolators and repeat steps one
through 4, for the opposite side.
DR BODY ISOLATORS (Continued)
EXTERIOR
23 - 37
Fig.1BODYISOLATORS-TYPICAL
1 - CAB SILL 2 - ISOLATORS 3 - REBOUND CUSHION 4 - WASHER (REAR ISOLATOR ONLY) 5 - BOLTS 6 - REINFORCEMENT PLATE (REAR ISOLATOR ONLY)
INSTALLATION
Fig.2SHORTCARGOBOX
1 - CARGO BOX 2 - FRAME 3 - BOLTS (3 PER SIDE)
(1) For the rear isolators install the rebound cush- ions, washers, reinforcement plates and bolts. (Fig. 1) (2) Install the remaining rebound cushions and
bolts.
(3) Tighten the bolts to 81 N·m (60 ft. lbs.).
CARGO BOX REMOVAL
(1) Disconnect the fuel fill hose and vent hose. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/ FUEL TANK - REMOVAL)
(2) Disconnect the tail lamp wire harness. (3) Remove the cargo box bolts. (Fig. 2) or (Fig. 3) (4) Remove the cargo box.
INSTALLATION
(1) Install the cargo box and install the bolts. (2) Tighten the bolts to 108 N·m (80 ft. lbs.). (3) Connect the fuel fill and vent hoses. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - INSTALLATION)
(4) Connect the tail lamp wire harness.
Fig.3LONGCARGOBOX
1 - CARGO BOX 2 - FRAME 3 - BOLTS (4 PER SIDE)
CARGO BOX - TIE DOWN REMOVAL
(1) Remove the bolts and remove the tie down
cleat. (Fig. 4)
INSTALLATION
(1) Install the tie down cleat and install the bolts. (2) Tighten the bolts to 34 N·m (25 ft. lbs.).
EXTERIOR
23 - 38
CARGO BOX - TIE DOWN (Continued)DR
Fig.4TIEDOWNCLEAT
1 - BOLTS (2) 2 - CLEAT
COWL GRILLE REMOVAL
(1) Remove the wiper arms. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER REMOVAL)
ARMS
(2) Disconnect the washer hose. (3) Remove the hood seal. (4) Remove the six push pin fasteners from the
front of the grille. (Fig. 5)
(5) Remove the two rear corner screws and remove
the grilles.
INSTALLATION
screws.
front of the grille.
(1) Install the grill and install the two rear corner
(2) Install the six push pin fasteners along the
(3) Install the hood seal. (4) Connect the washer hose. (5) Install the wiper arms. (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL- LATION)
panel.
Fig.5COWLGRILLE
1 - PUSH PIN FASTENERS (6) 2 - COWL GRILLE 3 - SCREWS (2)
EXTERIOR NAME PLATES REMOVAL
NOTE: Exterior name plates are attached to body panels with adhesive tape.
(1) Apply a length of masking tape on the body, parallel to the top edge and one end of the name plate to use as a guide for installation, if necessary. temperature is below 21°C (70°F) warm emblem with a heat lamp or gun. Do not exceed 52°C (120°F) when heating name plate.
(2) If
(3) Using a trim stick C-4755 or equivalent,
remove and discard the name plate.
INSTALLATION
(1) Thoroughly clean all residue from the name
plate attachment area of the body panel.
(2) Wipe area with a clean lint free cloth moist- ened with a 50% solution of water and alcohol and wipe dry immediately with a dry lint free cloth.
(3) Remove protective cover from adhesive tape on
back of name plate.
(4) Position name plate properly on the body
(6) If
(5) Apply consistent and uniform pressure over the entire surface of the name plate, with palm of hand. temperature is below 21°C (70°F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52°C (120°F) when heating name plate.
DR
FRONT FENDER REMOVAL
(1) Remove the antenna, if equipped. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA BODY & CABLE - REMOVAL)
(2) Remove the battery tray, if required. (Refer to 8
ELECTRICAL/BATTERY
SYSTEM/TRAY
REMOVAL)
(3) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(4) Remove the headlamp unit. (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD- LAMP UNIT - REMOVAL)
(5) Remove the wheelhouse splash shield. (Refer to - BODY/EXTERIOR/FRONT WHEELHOUSE
23
SPLASH SHIELD - REMOVAL)(6) Remove the inside and lower bolts. (Fig. 6) (7) Remove the two bolts below the headlamp. (8) Remove the hinge support bolt at the cowl. (9) Remove the three bolts along the fender rail.
Fig.6FRONTFENDER
1 - HOOD HINGE SUPPORT BOLT (1) 2 - HOOD HINGE 3 - INNER BOLT (1) 4 - FRONT BOLTS (2) 5 - LOWER BOLT INSERT 6 - FENDER 7 - UPPER BOLTS (3)
INSTALLATION
(1) Install the three bolts along the upper fender
rail and tighten to 9 N·m (80 in. lbs.).
(2) Install the upper hinge support bolt at the cowl
and tighten to 17 N·m (13 ft. lbs.).
(3) Install the two bolts below the headlamp and
tighten to 9 N·m (80 in. lbs.).
(4) Install the inside and lower bolts and tighten
to 17 N·m (13 ft. lbs.).
(5) Check the fender positioning and adjust as (Refer to 23 - BODY/
required by adding shims.
EXTERIOR
23 - 39
BODY STRUCTURE/GAP AND FLUSH - SPECIFI- CATIONS)
(6) Install the wheelhouse splash shield. (Refer to - BODY/EXTERIOR/FRONT WHEELHOUSE
23
SPLASH SHIELD - INSTALLATION)(7) Install the headlamp unit. (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD- LAMP UNIT - INSTALLATION)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the battery tray, if required. (Refer to 8
ELECTRICAL/BATTERY
SYSTEM/TRAY
INSTALLATION)
(10) Install the antenna, if required. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA BODY & CABLE - INSTALLATION)
FUEL FILL DOOR REMOVAL
(1) Open fill door and remove the bolts. (Fig. 7) (2) Remove the door.
Fig.7FUELFILLDOOR
1 - FUEL FILL DOOR 2 - BOLTS (2)
INSTALLATION
(1) Install the fuel fill door. (2) Install the bolts and tighten to 9 N·m (80 in.
lbs.).
GRILLE REMOVAL
(1) Open the hood. (2) Remove the six lower screws. (Fig. 8) (3) Remove the six upper nuts and separate the
grille from the grille frame.
EXTERIOR
23 - 40
GRILLE (Continued)DR
Fig.8GRILLE
Fig.9GRILLEFRAME
1 - HOOD 2 - GRILLE FRAME 3 - SCREWS (6)
(2) Remove the electrical connector push pin fas-
(3) Remove the five inside screws and remove the
tener.
splash shield.
1 - NUTS (6) 2 - HOOD 3 - GRILLE 4 - GRILLE FRAME 5 - SCREWS (6)
INSTALLATION
(1) Position the grille onto the grille frame. (2) Install the six upper nuts. (3) Install the six lower screws.
GRILLE FRAME REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the screws and remove the grille
frame. (Fig. 9)
INSTALLATION
screws.
(1) Install the grille frame and install the six
(2) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
FRONT WHEELHOUSE SPLASH SHIELD REMOVAL
(1) Remove the three screws at the fender. (Fig.
10)
Fig.10FRONTSPLASHSHIELD
1 - FENDER RAIL 2 - FENDER 3 - SCREWS (8) 4 - WHEELHOUSE SPLASH SHIELD
DR FRONT WHEELHOUSE SPLASH SHIELD (Continued) INSTALLATION
EXTERIOR
23 - 41
(1) Install the splash shield and position the front
edge into the support bracket on the bumper.
(2) Install the five inner screws. (3) Install the three screws at the fender. (4) Install the electrical connector push pin fas-
tener.
REAR WHEELHOUSE SPLASH SHIELD REMOVAL
(1) Remove the screws and remove the shield. (Fig.
11)
Fig.11REARSPLASHSHIELD
1 - CARGO BOX 2 - SCREWS (3) 3 - SPLASH SHIELD
INSTALLATION
(1) Install the splash shield and install the screws.
SIDE VIEW MIRROR REMOVAL
Fig.12SIDEVIEWMIRROR
1 - MIRROR 2 - NUTS (3) 3 - ELECTRICAL CONNECTOR
(1) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL) (2) Disconnect the electrical connector and remove
the nuts. (Fig. 12)
(3) Squeeze the electrical
connector
tabs and
Fig.13MIRRORELECTRICALCONNECTOR
remove the mirror. (Fig. 13)
INSTALLATION
(1) Install the mirror onto the door and engage the
electrical connector tabs. (Fig. 13)
(2) Install the nuts and tighten to 7 N·m (60 in.
lbs.).
1 - DOOR 2 - MIRROR STUDS 3 - CONNECTOR TABS 4 - ELECTRICAL CONNECTOR
(3) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
23 - 42
EXTERIOR
UPPER RADIATOR CROSSMEMBER REMOVAL
(1) Remove the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(2) Remove the radiator and condenser bolts. (Fig.
(3) Remove the bolts and remove the crossmember.
14)
(Fig. 15)
Fig.14CONDENSER/RADIATORFASTENERS
1 - CONDENSER BOLT 2 - RADIATOR BOLT 3 - RADIATOR CROSSMEMBER
DR
INSTALLATION
(1) Install the crossmember and install the bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Install the radiator and condenser bolts and
tighten to 8 N·m (75 in. lbs.).
(4) Install the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - INSTALLATION)
SIDE VIEW MIRROR GLASS REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO- TECTION WHEN SERVICING THE MIRROR ASSEM- BLY. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BRO- KEN GLASS.
Standard Mirror
(1) Position the mirror glass so that it’s facing in
toward the vehicle as far as possible. (Fig. 16)
(2) Disengage the rear housing cover retaining
tabs and remove the cover. (Fig. 17)
(3) Disengage the lower glass retaining tab to
motor. (Fig. 18)
(4) Slide glass up and remove from motor. (5) Disconnect the two heated mirror electrical
connectors, if equipped.
Fig.15RADIATORCROSSMEMBER
1 - BOLTS (2) 2 - CROSSMEMBER 3 - BOLTS (2)
Fig.16STANDARDMIRRORPOSITION
1 - RETAINING TABS (2) 2 - MIRROR HOUSING 3 - MIRROR GLASS
DR SIDE VIEW MIRROR GLASS (Continued)
EXTERIOR
23 - 43
Fig.17STANDARDMIRRORHOUSINGCOVER
Fig.19TOWPACKAGEMIRRORPOSITION
1 - MIRROR HOUSING COVER 2 - RETAINING TABS (3)
1 - MIRROR HOUSING ASSEMBLY 2 - MIRROR GLASS RETAINING CLIP 3 - MIRROR GLASS
Fig.18STANDARDMIRRORRETAININGTAB
1 - MIRROR ASSEMBLY 2 - MIRROR GLASS LOWER RETAINING TAB
Tow Package Mirror
Fig.20TOWPACKAGEMIRRORGLASS
1 - HEATED GLASS ELECTRICAL CONNECTORS (IF EQUIPPED) 2 - MIRROR GLASS 3 - RETAINING CLIP
(1) Position the mirror in the out position. (Fig. 19) (2) Release the retaining clip and separate the
glass.
(3) Disconnect the four heated glass electrical con-
nectors, if equipped. (Fig. 20)
EXTERIOR
23 - 44
SIDE VIEW MIRROR GLASS (Continued) INSTALLATIONStandard Mirror
DR
Tow Package Mirror
(1) Make sure the retaining clip is seated in the
closed position on the mirror glass.
(1) Connect the two heated mirror electrical con-
(2) Connect the heated mirror electrical connec-
nectors, if equipped. (Fig. 21)
(2) Position the mirror glass mounting holes over the four feet of the mirror motor and slide down. (Fig. 22)
(3) Engage the lower glass retaining tab to the
motor. (Fig. 18)
(4) Position the rear housing cover and seat the
retaining tabs fully. (Fig. 17)
tors, if equipped.
NOTE: Pressure must be applied equally over the center portion of the mirror to engage the mirror glass retaining clip fully.
(3) Position the glass over the motor mounting and
seat fully. Make sure the retaining clip seats fully.
REAR FENDER REMOVAL
(1) Remove the wheel house splash shield. (Refer to 23 - BODY/EXTERIOR/REAR WHEELHOUSE SPLASH SHIELD - REMOVAL)
(2) Disconnect the marker lamps electrical connec-
tors.
(3) Remove the tail
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ TAIL LAMP UNIT - REMOVAL)
lamp units.
(4) Remove the two fender nuts. (Fig. 23) (5) Remove the rear inner nuts below the tail
lamp. (Fig. 24)
(6) Remove the two bolts at the rear bottom edge. (7) Remove the two bolts at the front bottom edge. (8) Remove the four inner nuts front edge. (Fig.
25)
brackets. (Fig. 26)
(9) Loosen bolts and loosen the two fender support
CAUTION: Mask off the surrounding box area to avoid damage to the painted surfaces.
(10) Lift the fender up off the support brackets
and remove the fender.
INSTALLATION
CAUTION: Mask off the surrounding box area to avoid damage to the painted surfaces during instal- lation.
(1) Carefully position the fender over the support
brackets.
(2) Install the four inner nuts along the front edge
of the fender and tighten to 7 N·m (60 in. lbs.).
(3) Install the two inner nuts along the rear edge of the fender below the tail lamp unit and tighten to 7 N·m (60 in. lbs.).
(4) Tighten the six support bracket bolts and
tighten to 11 N·m (8 ft. lbs.).
Fig.21STANDARDMIRRORINSTALLATION
1 - MIRROR GLASS 2 - UPPER AND LOWER RETAINING CLIPS 3 - HEATED MIRROR ELECTRICAL CONNECTORS (IF EQUIPPED) 4 - MIRROR GLASS MOUNTING HOLES (4)
Fig.22STANDARDMIRRORASSEMBLY
1 - HEATED MIRROR ELECTRICAL CONNECTORS (IF EQUIPPED) 2 - MIRROR HOUSING 3 - HOUSING COVER LOCKING TABS 4 - MIRROR GLASS MOUNTING FEET (4)
DR REAR FENDER (Continued)
EXTERIOR
23 - 45
Fig.25LOWERFRONTFASTENERS
1 - PICK-UP BOX INNER PANEL 2 - FRONT FENDER NUTS (4)
Fig.23TAILLAMPOPENING
1 - TAIL LAMP OPENING 2 - FENDER NUTS (2)
Fig.26SUPPORTBRACKET
1 - FENDER SUPPORT BRACKET (2) 2 - PICK-UP BOX 3 - BOLTS (3 PER BRACKET)
Fig.24LOWERREARFASTENERS
1 - REAR FENDER NUTS (2) 2 - PICK-UP BOX INNER PANEL
(5) Install the bolts along lower edge of the fender
and tighten to 7 N·m (60 in. lbs.).
(6) Connect the marker lamps electrical connec-
tors.
(7) Install the wheelhouse splash shield. (Refer to - BODY/EXTERIOR/REAR WHEELHOUSE
23
SPLASH SHIELD - INSTALLATION)(8) Install the two nuts from within the tail lamp
opening and tighten to 7 N·m (60 in. lbs.).
(9) Install the tail lamp unit. (Refer to 8 - ELEC- EXTERIOR/TAIL
TRICAL/LAMPS/LIGHTING LAMP UNIT - INSTALLATION)
23 - 46
HOOD
HOOD
TABLE OF CONTENTS
page
DR
page
HINGE
LATCH RELEASE CABLE/HANDLE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47HOOD
LATCH STRIKER / SECONDARY CATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48LATCH
SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49HINGE REMOVAL
NOTE: It is not necessary to remove the hood to replace one or both hinges. The hinges can be replaced one at a time.
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
position of the hinge on the hood.
(3) Remove the fender support bolt. (Fig. 1) (4) Remove the support cylinder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLINDER - REMOVAL)
(5) Remove the hood nuts. (6) Remove the wheelhouse splash shield. (Refer to - BODY/EXTERIOR/FRONT WHEELHOUSE
23
SPLASH SHIELD - REMOVAL)(7) From inside the fender, remove the two hinge
(8) Slide the hinge forward and remove from the
bolts. (Fig. 2)
fender rail.
INSTALLATION
on the fender rail.
(1) Install the hinge and slide back into position
(2) From inside the fender, install the two hinge
bolts and tighten to 20 N·m (15 ft. lbs.).
(3) Install the hood nuts and line up the marks
made previously.
(4) Tighten the nuts to 23 N·m (17 ft. lbs.). (5) Install the support cylinder.
(Refer to 23 - BODY/HOOD/SUPPORT CYLINDER - INSTALLA- TION)
Fig.1HINGE/FENDERBOLT
1 - FENDER 2 - FENDER SUPPORT BOLT 3 - HINGE
(6) Install the fender support bolt and tighten to
11 N·m (8 ft. lbs.).
(7) Check hood fit and adjust if required. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the wheelhouse splash shield. (Refer to - BODY/EXTERIOR/FRONT WHEELHOUSE
23
SPLASH SHIELD - INSTALLATION)DR HINGE (Continued)
HOOD
23 - 47
Fig.2HINGE
1 - A-PILLAR 2 - HINGE 3 - BOLTS (2)
HOOD REMOVAL
(1) Open the hood. (2) Using a grease pencil or equivalent, mark the
position of the hinges on the hood.
(3) Remove the hood hinge nuts and remove the
hood.
(4) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(5) Remove the hood lamp and ambient tempera-
ture sensor.
INSTALLATION
sensor.
(1) Install the hood lamp and ambient temperature
(2) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
(3) Install the hood and install the nuts. (4) Line up the marks made previously and
tighten the nuts to 23 N·m (17 ft. lbs.).
(5) Check the hood fit and adjust if required. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
LATCH REMOVAL
(1) Open the hood. (2) Using a grease pencil or equivalent, mark the
position of the latch on the radiator crossmember.
(3) Remove the bolts. (Fig. 3) (4) Disconnect the hood latch cable and remove the
latch.
Fig.3LATCH
1 - HOOD LATCH 2 - HOOD LATCH CABLE 3 - BOLTS (2)
INSTALLATION
(1) Connect the hood latch cable. (2) Install the latch lining up the marks made pre-
viously and install the bolts.
(3) Tighten the bolts to 11 N·m (8 ft. lbs.). (4) Check hood fit and adjust if required. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
LATCH RELEASE CABLE/ HANDLE ASSEMBLY REMOVAL
(1) Remove the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(2) Remove the batter tray. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - REMOVAL)
(3) Disconnect the three cable push pin fasteners. (4) From inside the cab loosen the two handle screws and disconnect the handle from the instru- ment panel bracket.
(5) Separate the grommet at the cowl panel and
remove cable through the cab.
INSTALLATION
(1) Route the cable/handle assembly through the
cowl panel and install the grommet.
(2) Position the handle onto the instrument panel
bracket and tighten the screws.
(3) Route the cable along the fender rails and
install the three push pin fasteners.
(4) Install the latch. (Refer to 23 - BODY/HOOD/
LATCH - INSTALLATION)
(5) Install the battery tray. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION)
23 - 48
HOOD
LATCH STRIKER / SECONDARY CATCH REMOVAL
(1) Disconnect and remove the secondary release
(2) Remove the two bolts and remove the striker/
handle. (Fig. 4)
catch assembly.
Fig.4HOODLATCHSTRIKER/SECONDARYCATCH 1 - GRILLE 2 - LATCH STRIKER/SECONDARY CATCH 3 - BOLTS (2) 4 - SECONDARY CATCH RELEASE HANDLE 5 - GRILLE FRAME
INSTALLATION
(1) Install the latch striker/secondary catch and
install the bolts.
secondary catch.
(2) Tighten the bolts to 11 N·m (8 ft. lbs.). (3) Install the release handle and connect to the
(4) Check the hood fit and adjust if required. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
DR
SUPPORT CYLINDER REMOVAL
NOTE: The support cylinders can be replaced one at a time.
(1) Open the hood and support.
NOTE: Lift the clips only enough to release the ball studs. (Fig. 6)
(2) Using a small flat bladed tool, or equivalent, release the upper retaining clips while pulling the ball socket away from the ball stud. (Fig. 5)
CAUTION: Do not pull the supports from the middle while removing.
(3) Pulling at the ends only, remove the support
cylinder.
Fig.5UPPERSUPPORTCYLINDERREMOVAL-
TYPICAL
1 - BALL SOCKET 2 - RETAINING CLIP 3 - FLAT BLADED TOOL 4 - BALL STUD
DR SUPPORT CYLINDER (Continued)
HOOD
23 - 49
INSTALLATION
(1) Make sure the retaining clips are seated into
the ball socket fully.
CAUTION: Do not install the support cylinders by pressing at the center of the cylinder. Press the ends only.
(2) Install the support cylinder over the ball studs with the thin end connected to the body side of the hinge and the retaining clips snapping into place.
Fig.6UPPERSUPPORTCYLINDERRETAINING
CLIP
1 - RETAINING CLIP 2 - BALL SOCKET 3 - BALL STUD
23 - 50
INSTRUMENT PANEL
INSTRUMENT PANEL
TABLE OF CONTENTS
page
DR
page
CLUSTER BEZEL
INSTRUMENT PANEL CENTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58ASH RECEIVER
INSTRUMENT PANEL DRIVER SIDE BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59CUP HOLDER
INSTRUMENT PANEL TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60GLOVE BOX
INSTRUMENT PANEL LOWER SURROUND
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60GLOVE BOX LATCH
STEERING COLUMN OPENING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61INSTRUMENT PANEL ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56INSTRUMENT PANEL HEADLAMP SWITCH
BEZEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57STEERING COLUMN OPENING SUPPORT
BRACKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62STORAGE BIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62CLUSTER BEZEL REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRU- MENT PANEL COMPONENT DIAGNOSIS OR SER- VICE. 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.
(1) Remove the headlamp switch bezel. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL SWITCH BEZEL - REMOVAL)
(2) Remove the center bezel. (Refer to 23 - BODY/ PANEL
PANEL/INSTRUMENT
INSTRUMENT CENTER BEZEL - REMOVAL)
(3) Remove the two top screws. (Fig. 1) (4) Using a trim stick C-4755 or equivalent, sepa-
rate the two lower clips.
(5) Disengage the two top attachment bosses and
remove the bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRU- MENT PANEL COMPONENT DIAGNOSIS OR SER- VICE. 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.
(1) Position the cluster bezel over the cluster and seat the outer bosses over the posts on the left and right sides.
DR CLUSTER BEZEL (Continued)
2)
INSTRUMENT PANEL
23 - 51
(1) Open ash receiver and place hand inside. (Fig.
(2) Apply force with an abrupt downward motion
and roll rearward. (Fig. 3)
(3) Dislodge and roll ash receiver out of panel to
remove.
Fig.1CLUSTERBEZEL
1 - DASH PANEL 2 - SCREWS (2) 3 - CLUSTER BEZEL 4 - CLIP FASTENERS (2)
(2) Snap the top edge of the bezel into place fully. (3) Seat the two bottom clips fully. (4) Install the two top screws. (5) Install the center bezel (Refer to 23 - BODY/ PANEL
PANEL/INSTRUMENT
INSTRUMENT CENTER BEZEL - INSTALLATION)
(6) Install the headlamp switch bezel. (Refer to 23
PANEL/INSTRUMENTPANEL SWITCH BEZEL - INSTALLATION)
BODY/INSTRUMENT
Fig.2ASHRECEIVER
1 - ASH RECEIVER 2 - CUP HOLDER
ASH RECEIVER REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRU- MENT PANEL COMPONENT DIAGNOSIS OR SER- VICE. 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.
Fig.3ASHRECEIVERREMOVAL
1 - LOCKING TABS 2 - ASH RECEIVER 3 - CUP HOLDER
INSTRUMENT PANEL
23 - 52
ASH RECEIVER (Continued) INSTALLATIONWARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRU- MENT PANEL COMPONENT DIAGNOSIS OR SER- VICE. 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.
(1) Seat the bottom of the receiver into position. (2) Pivot the receiver forward and seat the retain-
ing clips fully.
