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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.
CUP HOLDER 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 center bezel.(Refer to 23 - BODY/ PANEL
PANEL/INSTRUMENT
INSTRUMENT CENTER BEZEL - REMOVAL)
(2) Remove the airbag control module trim cover.
(3) Open the cupholder and fold down the inner
(Fig. 4)
panel.
(4) Remove the two inner screws. (Fig. 5) (5) Remove the remaining four screws and remove
the cup holder. (Fig. 6)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING
DR
Fig.4INSTRUMENTPANELCOVERS
1 - TOP COVER 2 - INSTRUMENT PANEL 3 - AIR BAG MODULE COVER 4 - SIDE COVER
Fig.5CUPHOLDER-INNERFASTENERS
1 - CUPHOLDER 2 - INNER SCREWS (2)
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.
DR CUP HOLDER (Continued)
INSTRUMENT PANEL
23 - 53
(3) Lift the box assembly off of the hinges and
remove.
INSTALLATION
(1) Engage the glove box hinges and partially
close.
(2) From the inside of the box press down on the rearward edge of the bin and raise the glove box fully past the stops.
(3) Check for proper glove box operation.
GLOVE BOX LATCH REMOVAL
(1) Remove the glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(2) Remove the 11 screws and separate the box
and inner panel from the outer door.
(3) Remove the two latch screws and remove the
latch.
INSTALLATION
(1) Install the latch and install the two screws. (2) Install the door inner cover and box and install
(3) Install the glove box. (Refer to 23 - BODY/IN- INSTALLA-
STRUMENT PANEL/GLOVE BOX - TION)
INSTRUMENT PANEL ASSEMBLY 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 left a-pillar trim. (Refer to 23 - BODY/INTERIOR/A-PILLAR TRIM/GRAB HANDLE - REMOVAL)
Fig.6CUPHOLDER-OUTERFASTENERS
1 - SCREWS (4) 2 - CUPHOLDER
(1) Install the cupholder and install the two upper
screws.
inner screws.
(2) Install the lower two screws (3) Fold down the inner cover and install the two
the 11 screws.
(4) Install the center bezel. (Refer to 23 - BODY/ PANEL
PANEL/INSTRUMENT
INSTRUMENT CENTER BEZEL - INSTALLATION)
(5) Install the airbag control module trim cover.
GLOVE BOX 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) Partially open the glove box. (2) From the inside of the box press down on the rearward edge of the bin and lower the glove box fully past the stops.
INSTRUMENT PANEL
23 - 54
INSTRUMENT PANEL ASSEMBLY (Continued)DR
(2) Remove the top cover. (Refer to 23 - BODY/IN- STRUMENT PANEL/INSTRUMENT PANEL TOP COVER - REMOVAL)
(3) Disconnect the headliner harness electrical con-
nector at the a-pillar.
(4) Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left side cover. (Fig. 20)
(5) Remove the steering column. STEERING/COLUMN - REMOVAL)
(Refer to 19 -
(6) Remove the two bolts at the column support
bracket. (Fig. 7)
Fig.8LEFTSIDEMOUNTING
1 - A-PILLAR 2 - DASH PANEL 3 - MOUNTING BOLTS (3)
Fig.9WIREHARNESSCONNECTORS
1 - BULKHEAD CONNECTORS 2 - INSTRUMENT PANEL HARNESS CONNECTORS
(14) Remove the floor console, if equipped. (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - REMOVAL)
(15) Remove the center bracket bolts. (Fig. 10)
Fig.7COLUMNSUPPORT
1 - INSTRUMENT PANEL CLUSTER BEZEL 2 - STEERING COLUMN SUPPORT BRACKET 3 - BOLTS
(7) Remove the left cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - REMOVAL)
(8) Remove the instrument panel drivers side bezel. (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL DRIVERS SIDE BEZEL - REMOVAL)
(9) Remove the left side mounting bolts. (Fig. 8) (10) Disconnect the wire harness electrical connec-
tors above the brake pedal. (Fig. 9)
(11) Loosen the screws and remove the hood
release handle from the bracket.
(12) Disconnect
the park brake release handle
actuator rod.
if equipped. (Fig. 20)
(13) Remove the air bag control module trim cover,
DR INSTRUMENT PANEL ASSEMBLY (Continued)
INSTRUMENT PANEL
23 - 55
Fig.10CENTERMOUNTINGBOLTS
1 - INSTRUMENT PANEL 2 - BOLTS
(16) Disconnect the air bag control module electri-
cal connector.
(17) Remove the right cowl trim cover. (Refer to 23
- BODY/INTERIOR/COWL TRIM - REMOVAL)
(18) Disconnect the two electrical connectors. (Fig.
11)
Fig.11RIGHTWIREHARNESSCONNECTIONS
1 - COWL SIDE PANEL 2 - ELECTRICAL CONNECTORS
(19) Disconnect the radio antenna. (Fig. 12) (20) Remove the one HVAC screw. (Fig. 13)
Fig.12ANTENNACONNECTION
1 - ANTENNA CABLE 2 - RADIO CABLE
Fig.13HVAC/INSTRUMENTPANELMOUNTING
1 - HVAC 2 - MOUNTING SCREW 3 - LOWER SURROUND SCREWS 4 - GLOVE BOX OPENING
(21) Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right end cap. (Fig. 14)
(22) Remove the right a-pillar trim. (Refer to 23 - BODY/INTERIOR/A-PILLAR TRIM/GRAB HANDLE - REMOVAL)
(23) Remove the two right side mounting bolts on the a-pillar and one right mounting bolt on the cowl side panel. (Fig. 14)
INSTRUMENT PANEL
23 - 56
INSTRUMENT PANEL ASSEMBLY (Continued)DR
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 instrument panel assembly in
vehicle.
(2) Route the park brake release rod through the
instrument panel. (Fig. 16)
Fig.14PASSENGERSIDEMOUNTING
1 - DASH PANEL 2 - RIGHT SIDE MOUNTING HOOK 3 - A-PILLAR 4 - END CAP 5 - MOUNTING BOLTS (3)
(24) Remove the four top instrument panel screws.
(Fig. 15)
(25) Remove the two top instrument panel bolts
and remove the instrument panel.
Fig.15UPPERCOWLPANELBOLTS
1 - COWL PANEL 2 - FORWARD MOST SCREWS (4) 3 - BOLT INSERTS (6) 4 - REARWARD BOLTS (2) 5 - DASH PANEL
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING
Fig.16BRAKERELEASEROD
1 - PARK BRAKE RELEASE HANDLE 2 - PARK BRAKE RELEASE ROD 3 - INSTRUMENT PANEL
(3) Install the instrument panel onto the left side
guide pin and the right side guide hook.
(4) Install the left side mounting bolts and tighten
to 12 N·m (9 ft. lbs.).
(5) Install the instrument panel drivers side bezel. (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL DRIVERS SIDE BEZEL - INSTALLATION)
(6) Install the left cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - INSTALLATION)
(7) Connect the headliner harness electrical con-
nector at the a-pillar.
(8) Install the left a-pillar trim.
BODY/INTERIOR/A-PILLAR TRIM - TION)
(Refer to 23 - INSTALLA-
(9) Position the left end cap and seat the attach-
ment clips fully.
(10) Install the right side mounting bolts on the a-pillar and one right mounting bolt on the cowl side panel and tighten to 12 N·m (9 ft. lbs.).
DR INSTRUMENT PANEL ASSEMBLY (Continued)
INSTRUMENT PANEL
23 - 57
(11) Install the right a-pillar trim panel. (Refer to 23 - BODY/INTERIOR/A-PILLAR TRIM - INSTAL- LATION)
(12) Position the right end cap and seat
the
attachment clips fully.
(13) Install the one HVAC mounting screw. (14) Connect the radio antenna. (15) Connect the two electrical connectors at the
right cowl panel.
(16) Install the right cowl trim cover. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - INSTALLATION)
(17) Connect the air bag control module electrical
connector.
12 N·m (9 ft. lbs.).
(18) Install the center bracket bolts and tighten to
(19) Install the floor console, if equipped. (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - INSTAL- LATION)
(20) Install the air bag control module cover,
if
equipped.
tor rod.
the screws.
(21) Connect the park brake release handle actua-
(22) Install the hood release handle and tighten
(23) Install the two bolts at the column support
bracket and tighten to 14 N·m (10 ft. lbs.).
(24) Install the steering column.
(Refer to 19 -
STEERING/COLUMN - INSTALLATION)
(25) Connect the wire harness electrical connectors
above the brake pedal.
(26) Install the two top instrument panel bolts and
tighten to 12 N·m (9 ft. lbs.).
(27) Install the four top instrument panel screws. (28) Install the instrument panel top cover. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP COVER - INSTALLATION)
INSTRUMENT PANEL HEADLAMP SWITCH 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) Using a trim stick C-4755 or equivalent, release the top clips on the steering column opening cover and the lower drivers side bezel.
(2) Using a trim stick C-4755 or equivalent,
release the switch bezel. (Fig. 17)
(3) Disconnect the electrical connector and remove
the bezel.
Fig.17HEADLIGHTSWITCHBEZEL
1 - SWITCH BEZEL 2 - INSTRUMENT PANEL 3 - ELECTRICAL CONNECTOR 4 - HEADLIGHT SWITCH
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) Connect the electrical connector. (2) Position the switch bezel and seat the attach-
ment clips fully.
(3) Seat the clips on the steering column opening
cover and the lower drivers side bezel fully.
23 - 58
INSTRUMENT PANEL
DR
INSTRUMENT PANEL CENTER 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.
CAUTION: When removing and installing the center bezel, use tape or other suitable material to protect the cupholder and ash receiver from damage.
(1) Disconnect and isolate the negative battery
(4) Using a trim stick C-4755 or equivalent, gently pry the center bezel free from the instrument panel. (5) Working behind the center bezel, disconnect all
electrical connectors 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.
CAUTION: When removing and installing the center bezel, use tape or other suitable material to protect the cupholder and ash receiver from damage.
(1) Working behind the center bezel, connect all
(2) Gently install the center bezel on the instru- ment panel by pushing straight in and seat the attachment clips fully.
(3) Install the one center bezel screw. (4) Connect the negative battery cable.
cable.
(Fig. 18).
(2) Open the ashtray and cup holder. (3) Remove the one center bezel retaining screw
electrical connectors.
INSTRUMENT PANEL DRIVER SIDE 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.
Fig.18CENTERBEZEL
1 - INSTRUMENT PANEL 2 - CENTER BEZEL 3 - SCREW
CAUTION: Extreme care must be taken not to scratch the ashtray door while removing the instru- ment panel center bezel. Apply masking tape to the ashtray door if the center bezel is not being com- pletely removed from the instrument panel.
DR INSTRUMENT PANEL DRIVER SIDE BEZEL (Continued)
INSTRUMENT PANEL
23 - 59
(1) Using a trim stick C-4755 or equivalent, at notch in the bottom, remove the drivers side endcap. (2) Remove the drivers side cowl trim panel. (Refer to 23 - BODY/INTERIOR/COWL TRIM - REMOVAL)
(3) Remove the two screws. (Fig. 19) (4) Using a trim stick C-4755 or equivalent,
release the top clips and tilt the bezel down.
(5) Disconnect the adjustable pedal switch electri-
cal connector, if equipped.
(6) Lower the bezel down fully and remove from
the lower hooks.
Fig.19LOWERDRIVERSSIDEBEZEL
1 - SCREWS (2) 2 - ADJUSTABLE PEDAL SWITCH 3 - PEDAL SWITCH ELECTRICAL CONNECTOR 4 - 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 bezel onto the lower hooks and lift
up.
(2) Connect the adjustable pedal switch electrical
connector, if equipped.
(3) Seat the upper attachment clips fully. (4) Install the two screws. (5) Position the endcap and seat fully.
(6) Install the drivers side cowl trim panel. (Refer to 23 - BODY/INTERIOR/COWL TRIM - INSTALLA- TION)
INSTRUMENT PANEL TOP COVER 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) Using a trim stick C-4755 or equivalent, pry up on the rear of the top cover and release the attach- ment clips.
(2) Pull the top cover backwards to release the
remaining clips and remove the cover.
Fig.20INSTRUMENTPANELCOVERS
1 - TOP COVER 2 - INSTRUMENT PANEL 3 - AIR BAG MODULE COVER 4 - SIDE COVER
INSTRUMENT PANEL
23 - 60
INSTRUMENT PANEL TOP COVER (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) Position the top cover and fully seat the front
clips by pushing the cover forward and down.
(2) Fully seat the rear clips.
INSTRUMENT PANEL LOWER SURROUND 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) Using a trim stick C-4755 or equivalent, at notch in the bottom, remove the passenger side end- cap.
(2) Remove the passenger side cowl trim panel. (Refer to 23 - BODY/INTERIOR/COWL TRIM - REMOVAL)
(3) Remove the glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(4) Remove the cup holder, if equipped. (Refer to 23 - BODY/INSTRUMENT PANEL/CUP HOLDER - REMOVAL)
(5) Remove the storage bin, if equipped. (Refer to 23 - BODY/INSTRUMENT PANEL/STORAGE BIN - REMOVAL)
DR
(6) Remove the ash receiver. (Refer to 23 - BODY/
PANEL/ASH
RECEIVER
INSTRUMENT REMOVAL)
(7) Remove the steering column opening cover. (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - REMOVAL)
(8) Remove the 14 screws around the glove box
(9) Remove the nine remaining screws around the cup holder/storage bin and ash receiver area and remove the surround.
(10) Disconnect the 12v power outlet electrical con-
opening.
nector.
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) Install the surround and install all 23 screws. (2) Install the steering column opening cover. (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION)
(3) Install the storage bin, if equipped. (Refer to 23
- BODY/INSTRUMENT PANEL/STORAGE BIN - INSTALLATION)(4) Install the cup holder, if equipped. (Refer to 23
- BODY/INSTRUMENT PANEL/CUP HOLDER - INSTALLATION)(5) Install the glove box. (Refer to 23 - BODY/IN- INSTALLA-
STRUMENT PANEL/GLOVE BOX - TION)
(6) Install the ash receiver. (Refer to 23 - BODY/ INSTRUMENT PANEL/ASH RECEIVER - INSTAL- LATION)
(7) Install the passenger side cowl trim panel. (Refer to 23 - BODY/INTERIOR/COWL TRIM - INSTALLATION)
(8) Position the passenger side end cap and seat
fully.
DR
INSTRUMENT PANEL
23 - 61
STEERING COLUMN OPENING COVER 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 two lower screws. (Fig. 21) (2) Using a trim stick C-4755 or equivalent,
release the upper clips and remove the cover.
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 cover and seat the upper clips
fully.
(2) Install the two lower screws.
STEERING COLUMN OPENING SUPPORT BRACKET REMOVAL
(1) Remove the steering column opening cover. (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - REMOVAL)
(2) Remove the two screws and remove the diag-
nostic connector.
(3) Loosen the screws and remove the hood release
handle from the bracket.
(4) Remove the two bracket screws and slide
upward off the locating tabs to remove. (Fig. 22)
Fig.21STEERINGCOLUMNOPENINGCOVER
1 - SCREWS (2) 2 - COVER
INSTALLATION
Fig.22COLUMNOPENINGBRACKET
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRU-
1 - LOCATING TABS 2 - INSTRUMENT PANEL 3 - REINFORCEMENT BRACKET 4 - SCREWS (2)
INSTRUMENT PANEL
23 - 62
STEERING COLUMN OPENING SUPPORT BRACKET (Continued) INSTALLATIONDR
(1) Position the bracket onto the locating tabs and
(2) Install the two screws. (3) Install the diagnostic connector and install the
(4) Install the hood release handle and tighten the
slide down.
two screws.
screws.
(5) Install
the steering column opening cover. (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION)
STORAGE BIN 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 center bezel. (Refer to 23 - BODY/ PANEL
PANEL/INSTRUMENT
INSTRUMENT CENTER BEZEL - REMOVAL)
