Instrument Panel Carrier Assem. Inspect. &/or Reinforce. Pro.
INSTRUMENT PANEL CARRIER ASSEMBLY INSPECTIONAND/OR REINFORCEMENT PROCEDURE
Materials Needed:
^ 3/8 Inch Right Angle Drill Motor (Provided)
^ Hand-Held Hydraulic Rivet Tool (Provided)
^ 1/8 Inch and 1/4 Inch Drill Bits (Two of Each Provided)
SERVICE PRECAUTIONS
CAUTION:
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR SIR COMPONENTS OR SIR WIRING, YOU MUST DISABLE THE SIR SYSTEM. FAILURE TO FOLLOW THE CORRECT PROCEDURE COULD CAUSE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR UNNECESSARY SIR SYSTEM REPAIRS.
1. Disconnect negative battery cable.
2. Turn steering wheel so that vehicle's wheels are pointing straight ahead.
3. Turn ignition switch to LOCK and remove key.
4. Remove AIR BAG fuse from instrument panel fuse block (IPFB).
5. Disconnect driver yellow two-way connector; clipped to steering column brace.
IMPORTANT:
Do not remove upper trim panel. Passenger disconnect is accessible from underside of I/P
6. Detach clip holding passenger yellow two-way connector to metal brace, near HVAC fan.
7. Disconnect passenger yellow two-way connector.
NOTICE:
Do not remove door primary weatherstrip. Adhesion will be lost if removed.
8. Remove left endcap assembly:
a. Remove screws.
b. Carefully disengage endcap clips at I/P retainer locations. Use of a blunt tool will aid in disengaging clips.
c. Maneuver endcap assembly past inner I/P retainer assembly and weatherstrips.
d. Disconnect left door jamb switch connector by disengaging retaining tabs on connector.
9. Gently pry edges of ignition lock bezel with a blunt tool and separate from lower shroud.
10. Remove steering column upper shroud:
a. Remove two screws from long recessed holes in lower steering column shroud.
b. Lower steering column by pushing down on steering column adjusting handle.
c. Lift and remove upper shroud from steering column.
11. Remove dimmer/traction control switch assembly:
a. Use blunt tool to pry and depress retaining tab on left side of switch housing.
b. Depress wiring connector tabs and remove connectors from switch.
12. Remove I/P cluster bezel:
a. Disengage clips from retainer assembly by grasping edges of bezel near clip locations and pull outward.
13. Remove radio:
a. Remove radio screws.
b. Pull radio out slightly to access rear.
c. Disconnect electrical connector, antenna lead, and ground strap spade terminal.
14. Inspect I/P carrier assembly at locations indicated in illustration views A and B for structural fasteners already being installed.
^ If structural fasteners are already installed, go to step 22.
^ If the structural fasteners are not already installed, continue with next step.
15. Remove HVAC controller:
a. Remove screws.
b. Disconnect HVAC blower switch connector.
NOTICE:
When removing HVAC control cables, only pull at coiled ends of cable. Do not pull on straight wire section of cable. If straight wire section of cable is damaged or bent, effort required to rotate control knobs will increase.
d. Remove temperature control cable by squeezing lock tabs together while pulling cable (coiled end) straight up beyond retaining tabs.
e. Remove mode control cable by squeezing lock tabs together while pulling cable (coiled end) straight up beyond retaining tabs.
IMPORTANT:
Covering instrument panel fuse block (IPFB) is critical to prevent the possibility of metal shavings causing shorts at IPFB connections.
16. Cover IPFB and surrounding area with shop rags to collect metal shavings produced during the drilling process in next steps.
17. Using right angle drill and drill bit provided, drill 1/8 in. pilot holes in the following locations:
^ Left H-brace support between the two spot weld locations as indicated in View A: Left H-Brace.
IMPORTANT:
The following hole location is critical for a proper repair. All three layers of metal at H-brace support location must be retained by structural fastener.
^ Right H-brace support in upper rear corner of stamping as indicated in A View B: Right H-Brace.
18. Using right angle drill and drill bit provided, final drill both left and right pilot holes to proper diameter of 1/4 in.
IMPORTANT:
When compressing structural fastener, it may be necessary to release rivet tool and grip lower on compression stud.
19. In stall structural fastener (P/N 21127002) into drilled hole and use rivet tool provided to compress structural fastener until A compression stud pops free.
20. Vacuum any metal shavings from area of repair and carefully remove covering on IPFB ensuring no metal shavings fall free.
NOTICE:
When installing HVAC control cables, only push at coiled ends of cable. Do not push on straight wire section of cable. If straight wire section of cable is damaged or bent, effort required to rotate control knobs will increase.
IMPORTANT:
Make sure wiring harnesses do not interfere with control lever movement.
Cable identification:
^ Temperature control cable - white
^ Mode control cable - black
21. Install HVAC controller:
a. Install mode control cable onto mode control pin.
b. Snap slot on cable into HVAC controller base.
c. Install temperature control cable onto temperature control pin.
d. Snap slot on cable into HVAC controller base.
e. Install HVAC blower switch connector.
f. Install HVAC controller connector.
g. Install and torque screws.
Torque: 1.5 N.m (13 in-lbs)
22. Install radio:
a. Connect radio ground strap spade terminal.
b. Connect electrical connector.
c. Connect antenna lead.
d. Install radio by sliding it into guides on instrument panel.
e. Install and torque screws.
Torque: 2.5 N.m (22 in-lbs)
23. Install I/P cluster bezel:
a. Place dimmer/traction control switch assembly connectors through bezel opening.
b. Position I/P cluster bezel by lining up clip locations.
c. Snap I/P cluster bezel in place by pushing at clip locations.
24. Install upper steering column shroud:
a. Position upper steering column shroud.
b. Raise steering column by pushing down on steering column adjusting handle.
c. Install two retaining screws in long recessed holes in lower steering column shroud.
Torque: 1.5 N.m (13 in-lbs)
25. Install ignition bezel:
a. Align peg of ignition bezel with the cut out in lower shroud.
b. Snap into place.
26. Connect dimmer/traction control switch assembly connectors.
27. Install dimmer/traction control switch assembly into bezel opening.
IMPORTANT:
Ensure that endcap bottom portions are inside I/P filler panel.
28. Install left endcap assembly:
a. Connect left door jamb switch connector.
b. Maneuver endcap past inner I/P retainer assembly and door primary weatherstrip.
c. Snap clips into I/P retainer assembly locations.
d. Install screws.
Torque: 2.2 N.m (19 in-lbs)
29. Connect passenger yellow two-way connector.
30. Attach connector clip to metal brace near HVAC fan.
31. Connect driver yellow two-way connector and clip to steering column brace.
32. Install AIR BAG fuse in IPFB.
33. Connect negative battery cable.
Torque: 17 N.m (13 ft-lbs)
34. Verify the following are operating properly:
^ AIR BAG telltale
^ HVAC controls
^ Radio
^ Dimmer switch
^ Traction control switch (if equipped)