Dashboard / Instrument Panel: Service and Repair

WARNING:
- TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT CLASSIFICATION SYSTEM, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
- TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE OCCUPANT RESTRAINT CONTROLLER CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT.

CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules.

REMOVAL




1. Before proceeding with the following repair procedure, review all warnings and cautions.
2. Disconnect and isolate battery negative cable.
3. Using a trim stick C-4755 or equivalent, remove the left door sill trim cover.
4. Remove the screw and remove the left cowl trim cover.
5. Remove the left instrument panel end cap.
6. Remove the two screws (1) and remove the steering column opening cover (2).




7. Remove the screws (5) and position aside the hood release handle (2).




8. Remove the four screws (2) and remove the steering column opening reinforcement (1).




9. Remove the steering column tilt lever.
10. Remove the upper (1) and lower (3) column shrouds.




11. Disconnect the wiring harness connectors (1) to the column.
12. Remove the shift cable from the column shift lever actuator.
13. Release the shift cable from the column bracket and remove it from the bracket.
14. Remove the SKIM module in order to disconnect the electrical connector.




15. Remove the upper steering shaft coupler bolt (2) and slide the shaft (3) down.




16. Remove the brake light switch (5) and discard.




17. Remove the four steering column mounting nuts (3).
18. Lower the column from the mounting studs (1).
19. Remove the steering column assembly (2) from the vehicle.




Remove the pedal support bracket bolts.





20. Disengage the release rod (1) from the arm on the pedal assembly.





21. Disconnect the electrical connectors (1, 2 and 3) from the fuse block.
22. Remove the bolt and remove the ground wire (4).
23. Open the trim covers in the drivers side a-pillar grab handle and remove the bolts.
24. Remove the a-pillar trim panel.
25. Remove the floor console.




26. Disconnect the two body wire harness connectors
1. from the Occupant Restraint Controller (ORC)
2. connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector.




27. Position the carpet aside and remove the center harness screws (1). Pull instrument panel wiring harness (2) from under the carpet.




28. Remove the center support bolts.
29. Remove the drivers seat.
30. Remove the drivers side floor duct.




31. Remove the drivers side support bolts.




32. Remove the right instrument panel end cap.
33. Remove the passenger side support bolts.

Note: Drivers side shown, passenger side similar.




34. Using a trim stick C-4755 or equivalent, remove the right door sill trim cover.
35. Remove the screw and remove the right cowl trim cover.
36. Remove the bolts and remove the amplifier.
37. Disconnect the amplifier and antenna electrical connectors.




38. Remove the harness bolt (1) and the ground wire(3) bolt (2).
39. Remove the passenger side rear floor duct.




40. Open the trim covers in the passenger side a-pillar grab handle and remove the bolts.
41. Remove the a-pillar trim panel.
42. Using a trim stick C-4755 or equivalent, remove the instrument panel defroster grille.
43. Disconnect the sensor electrical connector (2).




44. Remove the four fenceline bolts (2).
45. Lift the instrument panel assembly (3) off the side support pins (1) and remove assembly through the drivers door.

INSTALLATION



1. Before proceeding with the following repair procedure, review all warnings and cautions.
2. Position the instrument panel assembly (3) into the vehicle through the drivers side door and install onto the side support pins (1).
3. Install the four fenceline bolts and tighten to 8 Nm (70 in. lbs.).




4. Connect the sensor electrical connector (2).
5. Install the instrument panel defroster grille and seat fully.
6. Position the passenger side a-pillar trim panel into place and seat fully.
7. Install the bolts and tighten to 6 Nm (55 in. lbs.).
8. Install the passenger side rear floor duct.




9. Install the screws for the ground wire (2) and passenger side wire harness (1).
10. Tighten the ground wire (2) and harness bolts (3) to 14 Nm (10 ft. lbs.).




11. Connect the amplifier and antenna electrical connectors.
12. Install the amplifier and install the bolts.
13. Tighten the bolts to 6 Nm (50 in. lbs.).
14. Install the right cowl trim cover and install the screw.
15. Install the right door sill trim cover.




16. Install the passenger side support bolts and tighten to 27 Nm (20 ft. lbs.).
17. Install the right instrument panel end cap.

Note: Drivers side shown, passenger side similar.

18. Install the drivers side support bolts and tighten to 27 Nm (20 ft. lbs.).




19. Install the drivers side floor duct.
20. Install the drivers seat.
21. Install the center support bolts and tighten to 11 Nm (95 in. lbs.).




22. Position the center instrument panel wiring harness (2) under the carpet and install the bolts (1).

CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged.




23. Reconnect the two body wire harness connectors (1) to the ORC connector receptacles located on the forward facing side of the module. Be certain that the latches on both connectors are each fully engaged.
24. Install the floor console.




25. Position the drivers side a-pillar trim into place and seat the retaining clips fully.
26. Install the bolts and tighten to 6 Nm (55 in. lbs.).
27. Install the ground wire (4) and install the bolt.
28. Tighten the ground wire bolts to 14 Nm (10 ft.lbs.)
29. Connect the electrical connectors (1, 2 and 3) at the fuse block.




30. Connect the brake release rod (1) to the arm on the pedal assembly.




31. Install the pedal support bolts and tighten to 14 Nm (10 ft. lbs.).

CAUTION: All fasteners must be torqued to specification to ensure proper operation of the steering column.




32. Position the steering column (2) on the dash panel support (1) and loosely install the mounting nuts (3).
33. Firmly slide the steering column (2) upward against the studs (1) in dash panel and hand tighten the nuts (3).




34. Install the steering shaft coupler (3) on the steering shaft (1) and loosely install a new bolt (2).




35. Center steering column (2) in dash opening and tighten mounting nuts (3) to 28 Nm (21 ft. lbs.).

Note:
- Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut.
- A new bolt must be used for reinstallation.

36. Tighten the coupler bolt to 38 Nm (28 ft. lbs.).




37. Install a new brake light switch (5).
38. Install the shifter cable.




39. Connect the wiring harness (1) to the column (2).
40. Install the SKIM module.




41. Install the upper (1) and lower (3) column shrouds and install the screws.
42. Install the column tilt lever.




43. Install the steering column opening reinforcement (1) and install the four screws.




44. Install the hood release handle (2) and install the screws (5).




45. Install the steering column opening cover (2) and install the two screws (1).
46. Install the left instrument panel end cap.
47. Instal the left cowl trim cover and install the screw.
48. Install the left door sill trim cover and seat fully.
49. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component.