Instrument Panel (I/P) Assembly Replacement

Instrument Panel (I/P) Assembly Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Disconnect the negative battery cable.
2. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the inlet heater hose at the heater core.
4. Remove the outlet heater hose at the heater core.
5. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
6. Remove the suction hose at the thermostatic expansion valve (TXV).
7. Remove the liquid line at the TXV.
8. Remove and discard the sealing washers.






Important: Plug the heater core pipes and the TXV opening to prevent coolant or polyalkylene glycol (PAG) oil from leaking into the interior.

Plug all A/C components immediately to prevent system contamination.

9. Disconnect the HVAC module to front of dash plate bolts.
10. Remove the right console trim panel.
11. Remove the left console trim panel.
12. Remove the console.
13. Remove the left closeout panel.
14. Remove both instrument panel (I/P) outer trim panels.




15. Remove the I/P to the body wire harness and antenna LH connectors.




16. Remove the I/P to the wire harness RH connectors.
17. Remove the knee bolster.
18. Remove the steering column to the I/P wire harness connector.




19. Remove the crush bracket to the front of dash plate nuts.
20. Remove the upper steering column shroud from the lower shroud.
21. Remove the stalk switches and the SIR coil connectors.
22. Position the steering wheel in full forward telescoping position.
23. Position the front seat in the full rearward position.
24. Remove the steering column mounting bolts.
25. Lower the steering column to the floor.
26. Remove the brake pedal assembly.
27. Remove the body control module (BCM).
28. Remove the center support bracket floor bolts.
29. Remove the shifter assembly.
30. Remove both windshield pillar garnish moldings.
31. Remove the I/P upper trim panel.




32. Remove the I/P body LH bolts.




33. Remove the I/P body RH bolts.
34. Remove the right hand floor heater duct at the center floor heater duct.
35. Remove the left hand floor heater duct at the center floor heater duct.
36. Remove the I/P assembly.




37. Remove and discard HVAC module drain seal and dash seal.

Installation Procedure

1. Install new HVAC module drain seal and dash seal.





2. Install the I/P assembly.
3. Install the left hand floor heater duct at the center floor heater duct.
4. Install the right hand floor heater duct at the center floor heater duct.






Notice: Refer to Fastener Notice in Service Precautions.

5. Install the I/P body RH bolts.

Tighten the bolts to 26 N.m (19 lb ft).




6. Install the I/P body LH bolts.

Tighten the bolts to 26 N.m (19 lb ft).

7. Install the I/P upper trim panel.
8. Install both windshield pillar garnish moldings.
9. Install the shifter assembly.
10. Install the center support bracket floor bolts.

Tighten the bolts to 10 N.m (89 lb in).

11. Install the BCM.
12. Install the brake pedal assembly.
13. Install the steering column assembly.
14. Install the stalk switches and the SIR coil connectors.
15. Install the upper steering column shroud from the lower shroud.




16. Install the crush bracket to the front of dash plate nuts.

Tighten the bolts to 10 N.m (89 lb in).

17. Install the steering column to the I/P wire harness connector.
18. Install the knee bolster.




19. Install the I/P to the body wire harness RH connectors.




20. Install the I/P to the body wire harness and antenna LH connectors.
21. Install both I/P outer trim panels.
22. Install the left closeout panel.
23. Install the console.
24. Install the left console trim panel Refer to Console Trim Panel Replacement - Left.
25. Install the right console trim panel.




26. Install the HVAC module to the MOD plate bolts.

Tighten the bolts to 4 N.m (35 lb in).

27. Unplug A/C components.
28. Install new sealing washers.
29. Install the liquid line at the TXV.
30. Install the suction hose at the TXV.
31. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
32. Leak test the fittings using the J 39400-A.
33. Install the outlet heater hose at the heater core.
34. Install the inlet heater hose at the heater core.
35. Fill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
36. Connect the negative battery cable.