Repair Procedure
REPAIR PROCEDURENOTE:
^ Read the entire REPAIR PROCEDURE to make sure you have the correct material to perform it.
^ Replace the cracked panel of the instrument panel with a modified one. DO NOT REPLACE THE DASHBOARD ASSEMBLY.
^ Stay out of direct sunlight.
^ Perform the repair in a well-ventilated area.
1. Verify customer concern.
2. Disconnect the battery terminals.
3. Remove the following interior pieces, referring to MS3 online instructions or the Workshop Manual:
4. On vehicles equipped with auto A/C, insert a flathead screwdriver to carefully pry and remove the solar radiation sensor (A) from the cracked panel, then disconnect the connector (B).
5. Insert a flathead screwdriver or equivalent tool (A) between the dashboard and the cracked panel (B) and pry up to separate the cracked panel from the dashboard.
Locations where flathead screwdriver (or equivalent tool) should be inserted.
6. Using a vacuum cleaner, remove dust/debris created while separating the cracked panel from the dashboard.
7. To prevent glue from sticking to the glass, attach paper or card stock (A) along the edge of the windshield using masking tape (B).
8. On vehicles equipped with auto A/C, wrap electrical tape around the solar radiation sensor connector (A) leaving about 20" that can be twisted to form a string.
NOTE:
This step is required to install the solar radiation sensor to the new panel.
9. Before applying adhesive, temporarily fit the new panel to check if it can be fitted with no problems.
NOTE:
Make sure you have the following items ready before you start gluing.
^ 5/8 ID rubber hose cut at an angle on one end -approximately 6-1/2 inches long on one side (A) and 5-5/8 inches long on the opposite side (B)
10. Carefully apply glue to the dashboard assembly where the cracked panel was fitted - see "Applying the Glue" procedure later in this document.
Glue application location on the dashboard shown with darker lines (or reference removed panel)
NOTE:
^ The bead of glue should be 3-4 mm.
^ Follow the directions/handling instructions on the label of the glue.
^ Be sure to thoroughly degrease the surface where the glue will be applied with rubbing alcohol.
^ For strong adhesion, be generous with the amount of glue.
^ Be sure to install the new panel within 10 minutes after the glue is applied, otherwise the glue will dry and lose adhesion.
NOTE:
Apply extra glue (A) on the center and sides of the dashboard.
11. On vehicles equipped with auto A/C, pass the tape of the solar radiation sensor connector (A) through the hole of the new panel (B).
NOTE:
Unlike the original panel, there is no seal tape on the bottom edge of the new panel.
12. Install the new panel on the dashboard, making sure to avoid damaging it.
NOTE:
You may have to remove the foam protective tape cover from the new panel so the tennis balls will stay in place.
13. Remove the paper and masking tape from the windshield installed earlier to prevent it from sticking to the panel.
NOTE:
If glue gets on the dash, remove it immediately with rubbing alcohol.
14. Press fit the new panel onto the dashboard from the center to the outside using the following steps.
a. Front-side edge: Push in rubber tube (A) between new panel and windshield.
b. Center and side area: Push the tennis balls (B) between the windshield and the new panel.
Press fit the adhered locations (Z) using the rubber hose (A) and tennis balls (B)
c. Center area: Press with rubber tube (C) using electrical tape to hold it in place between the dash panel center support (Y) and the windshield.
d. Passenger side near vent: Use a couple of zip ties (D) linked together to wrap the new panel to the dashboard.
NOTE:
Make sure there is sufficient tension and that the panel and dashboard are touching so that the glue bonds correctly.
e. Driver's side near vent: Use a couple of zip ties (E) linked together to hold the new panel in place.
NOTE:
Make sure there is sufficient tension and that the panel and dashboard are touching so that the glue bonds correctly.
f. Side areas: Place workshop manuals or equivalent 5 lbs (F) on dash just outside the tennis balls (B).
15. For proper adhesion, let the vehicle sit for more than 12 hours. After that, remove all the items installed to hold the new panel down.
NOTE:
^ For better ventilation, fully open all the vehicle windows.
^ Keep the panel out of direct sunlight.
16. Confirm that the panel is held in place. If any spots on the edge (circled) did not glue correctly, use the second nozzle to re-glue these areas.
NOTE:
The panel cannot be removed and reused.
17. Reinstall the parts in the reverse order of removal.
18. Verify repair.