Instrument Panel Top Cover Replacement

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

1. Disconnect and isolate the battery negative cable.
2. Remove the cluster bezel from the instrument panel.
3. Remove the park brake release handle from the instrument panel. See Brakes and Traction Control/Brakes/Parking Brake System/Parking Brake Release Motor/Park Brake Release Handle in the Replacement for the procedures.
4. Remove the glove box from the instrument panel. See Glove Box in the Replacement for the procedures.
5. Remove the glove box lamp and switch from the instrument panel.

Passenger Side Airbag Module Lower Bracket Screws:

6. Reach through and above the instrument panel glove box opening to remove the two screws that secure the passenger side airbag module lower bracket to the instrument panel.
7. Reach through the instrument panel glove box opening to access and unplug the passenger side airbag module wire harness connector. Disengage the connector retainer from the back of the instrument panel inboard glove box opening bracket.
8. Remove the heater and air conditioner control from the instrument panel.
9. Reach through the instrument panel heater A/C control opening to remove the screw that secures the flexible demister tube to the demister duct tee, and remove the tube from the tee.
10. Reach through the instrument panel heater A/C control opening to remove the screw that secures the demister duct tee to the instrument panel.
11. Remove the instrument panel from the vehicle and place it on a work bench.

Instrument Panel Top Cover Remove/Install:

12. Use a drill motor with a large drill bit, a high-speed grinder, or a soldering iron with a cutting tip to remove the collapsed heat stakes from the underside of the five instrument panel to dash panel mounting screw holes at or below the illustrated cut line. If the instrument panel top cover is to be reused, use care not to drill through or to enlarge the screw holes in the top cover. Using a trim stick or another suitable wide flat-bladed tool, gently pry between the top cover and the instrument panel base bracket near the heat stake during the removal process. This will cause the panels to separate noticeably when the collapsed heat stake has been sufficiently removed, and prevent the removal of too much material. After removal, the heat stakes should be flush with, or protruding no more than 4 millimeters (0.1875 inches) from the lower surface of the top cover.

NOTE: New instrument panel top covers are supplied with heat stakes that have not been collapsed. These heat stakes must also be removed in order to install the new top cover. Use a hack saw or razor knife to remove the heat stakes from a new top cover. See Step 12 for the heat stake removal details.

13. Remove the screws around the perimeter of the top cover that secure it to the instrument panel base.
14. Lift the top cover off of the instrument panel.

WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE INSTRUMENT PANEL TOP COVER AND THE PASSENGER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

15. Reverse the removal procedures to install. Tighten the passenger side airbag module lower bracket screws to 12 N.m (105 in. lbs.). Tighten the instrument panel top cover mounting screws to 2.2 N.m (20 in. lbs.).