Operation CHARM: Car repair manuals for everyone.

Modular Dash Assembly

MODULAR DASH ASSEMBLY

REMOVAL




1. Remove windshield.
2. Remove bolts from modular dash assembly and from cross car beam.
3. Disconnect negative battery cable.
4. Remove brake master cylinder.

NOTE: After removing brake line fitting nuts, do not excessively pull or bend brake lines away from master cylinder.

5. Remove brake line fitting nuts from master cylinder.

NOTE: Plug open lines and fittings to prevent brake fluid loss and contamination.

6. Remove two master cylinder-to-brake booster attachment nuts.

NOTE: Be careful not to bend brake lines.




7. Remove master cylinder.

CAUTION: WHEN USING TOOLS THAT MAY CREATE SMOKE WHEN CUTTING OR HEATING URETHANE ADHESIVE, WORK SHOULD BE DONE IN A WELL VENTILATED AREA AND/OR WITH A NIOSH/MSHA APPROVED AIR SUPPLIED RESPIRATOR TO PREVENT POSSIBLE HARMFUL EXPOSURE. WHEN THE URETHANE ADHESIVE IS HEATED ENOUGH TO GIVE OFF SMOKE, HIGH LEVELS OF METHYLENE DI-ISOCYANATE MAY BE PRESENT. UNPROTECTED EXPOSURE TO METHYLENE DI-ISOCYANATE MAY RESULT IN SEVERE, CHRONIC, DEBILITATING RESPIRATOR PROBLEMS.




8. Remove dash insulator.
9. Cut modular dash assembly above smile joint in area of dotted line.
10. Using piano wire, cut sealing joint to dash in the shock tower area.
11. Heat joint with a heat gun to loosen adhesive bond. Pull remainder of modular dash flange from the adhesive joint.
12. Remove old adhesive from smile joint. Clean joint areas with isopropyl alcohol in sealer path areas and prepare for new adhesive (P/N 12345633).

CAUTION: THIS JOINT MUST SEAL COMPLETELY IT MUST BE TESTED TO ENSURE THERE ARE NO WATER LEAKS OR PATHS FOR CARBON MONOXIDE TO INTRUDE INTO THE PASSENGER COMPARTMENT.




13. Apply adhesive into smile joint and sealing areas as shown in illustration.
14. Install dash ensuring proper engagement of the smile joint.







15. Check sealing of the dash assembly to front body hinge pillar (3), shock tower (2), windshield pillar (4), and instrument panel reinforcement panel (1). No water and air leaks are permissible.




16. Position master cylinder onto brake booster studs and install fastening nut.

Torque:
Master Cylinder-to-Brake Booster Nuts: 27 N.m (20 ft.lbs)


NOTE: Be careful not to bend brake lines.




17. Position brake lines into the master cylinder and secure brake line fitting nuts.

Torque:
Brake Line-to-Master Cylinder Nuts: 32 N.m (20 ft.lbs)


18. Install electrical connector for brake fluid level sensor switch.
19. Fill brake fluid reservoir with clean brake fluid up to base of the reservoir fill neck.
20. Bleed brake system.
21. Check brake fluid level.
22. Check for leaks with the engine running and brakes applied. Check also system performance.

When the vehicle is completely reassembled, performance check the following systems.
- All electrical systems.
- Braking systems.
- HVAC system.
- Steering system.
- Water leak test modular dash and windshield. Check all seams for water leaks and air leaks.
- Engine cooling system.
- Engine air intake system.