Instrument Panel
Instrument Panel - 4.0L (76.46.23/99)
Removal
1. Remove the intake manifold.
2. Evacuate the A/C system.
3. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
4. Drain the cooling system.
5. Remove the floor console.
6. Remove both cowl side trim panels.
7. Remove the driver side closing trim panel.
^ Release the clip.
^ Remove the 2 screws.
^ Disconnect the electrical connector.
8. Remove the passenger side closing trim panel.
^ Release the clip.
^ Remove the 2 screws.
^ Disconnect the electrical connector.
9. Release the door check strap from the A-pillar.
^ Remove the 2 Torx bolts.
10. NOTE: The door is still attached by its harness at this stage.
With assistance, release and support the door assembly.
^ Remove the 2 bolts.
11. Release the electrical connector from the A-Pillar.
^ Release the grommet.
^ Carefully release, then slide the latch to locate in the indents, arrowed.
12. Remove the door.
^ Release the grommet.
^ Release the electrical connector.
^ Disconnect the electrical connector.
13. Remove the front seats.
14. Release the transmission selector lever cable.
^ Remove the clip.
^ Release the cable.
15. Remove the transmission selector lever.
^ Remove the 4 bolts.
16. Disconnect the steering column intermediate shaft from the steering column.
^ Note the fitted position.
^ Remove the special bolt and discard the nut.
17. Disconnect 2 drain tubes from the heater housing.
18. Position the heater housing center ducts aside for access.
19. Remove 2 Torx bolts from the instrument panel center bracket.
20. Remove the instrument panel center speaker grille.
^ Release the 4 clips.
21. Remove the instrument panel upper section to body bolt.
22. Remove the plenum chamber panel.
23. Remove the instrument panel carrier to bulkhead Torx bolt.
24. CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Disconnect 2 heater hoses from the bulkhead.
^ Release the 2 clips.
25. Release 2 A/C lines from the body.
^ Remove the nut.
26. CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.
Release 2 A/C lines from the bulkhead.
^ Remove the bolt.
^ Remove and discard the O-ring seals.
27. Remove the 2 adapter panels.
^ Remove the 4 nuts.
28. Release the 3 ground cables from the driver side lower A-pillar.
^ Remove the 2 nuts.
29. Disconnect the 5 electrical connectors from the driver side lower A-pillar.
30. Release the 3 ground cables from the passenger side lower A-pillar.
^ Remove the 2 nuts.
31. Disconnect the 5 electrical connectors from the passenger side lower A-pillar.
32. Disconnect the heater motor electrical connector.
33. Disconnect 2 central junction box (CJB) electrical connectors.
34. Disconnect 2 electrical connectors from the instrument panel center reinforcement.
35. If installed, disconnect the instrument panel center reinforcement fibre optic cables.
^ Disconnect the electrical connector.
36. Driver side: Remove the heater housing to bulkhead Torx bolt.
37. Passenger side: Remove the heater housing to bulkhead Torx bolt.
38. With assistance, remove the instrument panel.
^ Remove the 4 Torx bolts.
Installation
1. With assistance, install the instrument panel.
^ Tighten the Torx bolts to 25 Nm (18 lb.ft).
2. Passenger side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
3. Driver side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
4. Connect the instrument panel center reinforcement fibre optic cables.
5. Connect the instrument panel center reinforcement electrical connectors.
6. Connect the CJB electrical connectors.
7. Connect the heater motor electrical connector.
8. Connect the electrical connectors to the passenger side lower A-pillar.
9. Connect the ground cables to the passenger side lower A-pillar.
^ Tighten the nuts to 10 Nm (7 lb.ft).
10. Connect the electrical connectors to the driver side lower A-pillar.
11. Connect the ground cables to the driver side lower A-pillar.
^ Tighten the nuts to 10 Nm (7 lb.ft).
12. Install the adapter panels.
^ Tighten the nuts to 10 Nm (7 lb.ft).
13. Secure the A/C lines to the bulkhead.
^ Clean the components.
^ Install new O-ring seals.
^ Tighten the bolt to 10 Nm (7 lb.ft).
14. Secure the A/C lines to the body.
^ Tighten the nuts to 10 Nm (7 lb.ft).
15. Connect the bulkhead heater hoses.
16. Install the instrument panel carrier to bulkhead Torx bolt and tighten to 25 Nm (18 lb.ft).
17. Install the plenum chamber panel.
18. Install the instrument panel upper section to body bolt and tighten to 10 Nm (7 lb.ft).
19. Install the speaker grille.
^ Secure with the clips.
20. Install the instrument panel center bracket Torx bolts and tighten to 25 Nm (18 lb.ft).
21. Attach the heater housing center ducts.
22. Connect the drain tubes to the heater housing.
23. Connect the steering column intermediate shaft.
^ Install the special bolt and tighten the new nut to 22 Nm (16 lb.ft).
24. Install the transmission selector lever.
^ Tighten the bolts to 10 Nm (7 lb.ft).
25. Attach the transmission selector lever cable.
^ Install the clip.
26. Install the front seats.
27. With assistance, install the door assembly.
^ Connect the electrical connector.
^ Secure the electrical connector.
^ Secure the grommet.
^ Tighten the bolts to 10 Nm (7 lb.ft).
28. Attach the door check strap to the 'A' pillar.
^ Tighten the Torx bolts to 10 Nm (7 lb.ft).
29. Install the driver side closing trim panel.
^ Connect the electrical connector.
^ Secure the clip.
^ Tighten the screws.
30. Install the passenger side closing trim panel.
^ Install the interior lamp.
^ Connect the electrical connector.
^ Secure the clip.
31. Install the cowl side trim panels.
32. Install the floor console.
33. Refill the cooling system.
34. Recharge the A/C system.
35. Install the intake manifold.