Instrument Panel - Installation

INSTALLATION





1. Position the I/P assembly into the vehicle and support the back.





2. Position the wire harness (2) through the cowl panel (1) and seat the grommet (3) fully.





3. Loosely install the nuts (3) onto the fenceline studs (1).
4. Position the I/P assembly (4) back and carefully push the heater core, A/C lines, and the brake booster support studs, through the cowl.
5. Position the I/P over the fenceline studs (1).





6. Loosely install the side support bolts (1).





7. Install the center support brackets (4) over the studs (3) and install the bolts (1) and nuts (2).





8. Tighten the side support bolts to 11 Nm (8 ft. lbs.).





9. Tighten the fenceline nuts to 12 Nm (9 ft. lbs.).





10. Tighten the bolts (1) and nuts (2) to 8 Nm (71 in. lbs.).





11. Position the main wire harness (1) back into place and seat all the support clips fully.





12. Install the brake booster bracket nuts (2) and tighten to 18 Nm (13.3 ft. lbs.).
13. Position the wire harness back and secure the support clips fully.





14. Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve ports.
15. Lubricate the new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings, as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
16. Connect the A/C liquid line (3) and A/C suction line (5), onto the A/C expansion valve (1).
17. Install the nut (2) that securing the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.).





18. Remove the previously installed plugs or caps and connect the heater hoses (2) to the heater core tubes (1).
19. Using the cable-type spring clamp pliers or equivalent, correctly position the two hose clamps securing the heater hoses to the heater core tubes and engage the clamps to the tubes.





20. Install the EGR tube (1), Exhaust Gas Recirculation (EGR) Valve - Installation.
21. Fill the coolant. Cooling System.
22. Evacuate the A/C system. Refrigerant System Evacuate.





23. Install the battery tray. Battery Tray - Installation.
24. Position the power steering reservoir back into place.
25. Install the right side grounds (2) and install the nuts (3).
26. Connect the positive battery cable (4).





27. Install the glove box (1). Instrument Panel Glove Box - Installation.





28. Connect the antenna connector (1).





29. Connect the electrical connectors (1 and 2).





30. Connect the grounds (2) and install the nuts.
31. Install the nut to the lower HVAC support bracket under the glove box.





32. Connect the brake pedal rod (1) and install the clip (2).
33. If equipped, connect the clutch pedal rod and install the clip.
34. Install the radio. Radio - Installation
35. Install the transfer case shifter. Transfer Case Lever - Installation
36. Install the automatic transmission shifter, if equipped.





37. Position the end caps (1) onto the I/P and seat fully.
38. Install the steering column. Steering Column - Installation
39. Install the amplifier. Amplifier - Installation
40. Install the steering column opening cover. Steering Column Opening Cover - Installation





41. Position the center harness (1) back into place and seat the support clips (2) fully.





42. Connect the center harness electrical connectors (1, 2 and 3).
43. Install the center console. Center Console - Installation





44. Connect the battery cables (4).





45. Secure the front door check straps (2) over the footmans loop (1) and connect the electrical connector (3).