Part 2 - HVAC sub assembly removal and installation

Part 4 - Blend door actuator removal and installation

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

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

2. With the aid of an assistant, load the instrument panel assembly through the driver side front door of the vehicle and hang it on the studs on the dash panel near the windshield fence line (Fig. 23).

3. Be certain that the molded plastic guide/pin formations on the instrument panel structural duct are inserted into and seated in the guide holes at each cowl side inner panel.

4. Loosely install the two screws that secure each end of the instrument panel to the cowl side inner panels.

5. Install the two screws that secure the passenger side instrument panel structural duct to the heater and air conditioner housing (Fig. 36), and tighten to 11 N·m (8 ft. lbs.).

6. Install the one screw that secures the instrument panel steering column support bracket to the driver side end of the heater and air conditioner housing (Fig. 29), and tighten the to 11 N·m (8 ft. lbs.).

Figure 29

Figure 36

7. Tighten the two screws that secure each end of the instrument panel to the cowl side inner panels (Fig. 33) and (Fig. 37), to 11 N·m (8 ft. lbs.).

Figure 33

Figure 37

8. Install the one screw that secures the instrument panel steering column support bracket to the intermediate bracket on the driver side dash panel (Fig. 30), and tighten to 11 N·m (8 ft. lbs.). 9. Tighten the three nuts that secure the instrument panel intermediate bracket and the accelerator pedal assembly to the studs on the dash panel to 11 N·m (8 ft. lbs.).

10. Install the safety strap and tighten the nut.

11. Install the four nuts that secure the instrument panel to the studs on the dash panel near the windshield fence line and tighten to 11 N·m (8 ft. lbs.).

12. Install the nut that secures the instrument panel steering column support bracket to the stud on the driver side cowl plenum panel (Fig. 31), and tighten to 28 N·m (21 ft. lbs.).

13. Install the instrument panel to center floor tunnel bracket onto the instrument panel and the floor panel transmission tunnel.

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

Figure 31

Figure 35

15. Connect the two halves of the radio antenna coaxial cable connector near the passenger cowl side inner panel under the end of the instrument panel.

16. Connect the instrument panel wire harness connector to the lower cavity of the inline connector on the passenger side cowl side inner panel and tighten the connector screw (Fig. 34). 17. Install the lower right center bezel onto the instrument panel.

18. Install the end cap onto the instrument panel.

19. Install the glove box.

20. If equipped with the manual heating and air conditioning system, connect the vacuum harness connector located near the driver side of the floor panel transmission tunnel behind the driver side floor duct.

21. Position the driver side floor duct to the heater and air conditioner housing near the driver side of the floor panel transmission tunnel (Fig. 29).

Figure 29

Figure 34

22. Install the one screw that secures the driver side floor duct to the heater and air conditioner housing near the driver side of the floor panel transmission tunnel.

23. Route the instrument panel wire harness to the floor panel transmission tunnel and engage the retainers that secure the harness to the mounting brackets on the tunnel (Fig. 28).

24. Install the instrument panel wire harness ground eyelets to the studs on the floor panel transmission tunnel in front of and behind the airbag control module and secure the eyelets with nuts and tighten to 7 N·m (60 in. lbs.).

25. Connect the instrument panel wire harness connectors to the following floor panel transmission tunnel components:

• The airbag control module (ACM) connector receptacle
• The park brake switch terminal
• The transmission shifter connector receptacle.

26. Connect the left and right body wire harness connectors, the ignition off draw (IOD) wire harness connector and the fused B(+) wire harness connector to the connector receptacles of the junction block (JB) and tighten the connector screws (Fig. 27).

27. Engage the lower steering column shaft with the steering shaft coupler and position the steering column to the mounting studs on the instrument panel steering column support bracket (Fig. 26).

Figure 26

Figure 27

28. Install the four nuts that secure the steering column to the studs on the instrument panel steering column support bracket and tighten to 11 N·m (8 ft. lbs.).

29. Install the bolt that secures the coupler to the lower steering column shaft and tighten to 49 N·m (36 ft. lbs.).

30. Turn the ignition switch to the On position, then install the shifter interlock cable connector into the ignition lock housing receptacle.

31. Connect the instrument panel wire harness connectors to the following steering column components (Fig. 25):

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

32. Position the lower tilting steering column shroud to the steering column multi-function switch mounting housing, then install and tighten the screw that secures the shroud to the housing (Fig. 24).

Figure 24

Figure 25

33. Position the upper tilting steering column shroud over the steering column. Align the upper and lower shrouds with each other and snap the two halves together.

34. Install the steering column bracket onto the instrument panel steering column support bracket.

35. Install the steering column opening cover.

36. Install the cluster bezel.

37. Install the fuse cover onto the Junction Block.

38. Install the console onto the floor panel transmission tunnel.

39. Install the trim panels onto the right and left inner cowl sides.

40. Install the scuff plates onto the right and left front door sills.

41. Install the instrument panel top cover.

42. Install the trim onto the right and left a-pillars.

43. Connect the battery negative cable.