Contents: Removal ⇩ Installation ⇩
Removal
1. Remove the engine cover. For more information, refer to Engine Cover - 4.4L (12.30.50)
2. Evacuate the air conditioning system. For more information, refer to Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (82.30.02)
3.
CAUTION: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.
Raise the vehicle and place it on supports.
4. Drain the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
5. Remove the floor console. For more information, refer to Floor Console (76.25.01)
6. Remove both door jamb trim panels. For more information, refer to Front Door Jamb Trim Panel (76.13.27)
7. Remove the decorative panel from the driver's side.
- Release the clamp.
- Remove 2 screws.
- Disconnect the electrical connector.
8. Remove the decorative panel from the passenger side.
- Release the clamp.
- Remove 2 screws.
- Disconnect the electrical connector.
9. Disconnect the door opening limiter from the front body pillar. Unscrew the 2 Torx head bolts.
10.
NOTE: At this stage the door is still secured with the appropriate fasteners.
With outside help, release the door assembly and install it on the supports. Unscrew 2 bolts.
11. Disconnect the electrical connector from the front body pillar.
- Remove the sealing sleeve.
- Carefully release and then slide the latch to insert it into the recesses marked with arrows.
12. Remove the door. Disconnect the electrical connector.
13. Remove the front seats. For more information, refer to Front Seat (78.10.44/99)
14. Release the gear selector lever cable.
- Remove the clamp.
- Release the cable.
15. Remove the gear selector lever. Unscrew the 4 bolts.
16. Disconnect the intermediate steering column shaft from the steering column.
- Remember the position in which the parts are installed.
- Unscrew the special bolt and discard the nut.
17. Disconnect the 2 drain tubes from the heater body.
18. Move the central heater ducts to the side to gain access.
19. Remove the 2 Torx head bolts from the instrument panel center bracket.
20. Remove the center speaker grille from the instrument panel. Release the 4 clips.
21. Remove the bolt securing the upper part of the instrument panel to the body.
22. Remove the mixing chamber panel. For more information, refer to Accumulating Chamber (80.15.62)
23. Remove the Torx head bolt securing the instrument panel brackets to the body.
24.
CAUTION: Before disconnecting or removing components, clean the area around the contact surfaces and connections. To avoid contamination of the system, plug all open connections.
Disconnect the 2 heater hoses from the bulkhead. Release the 2 clamps.
25. Disconnect the 2 air conditioning pipes from the body. Unscrew the nut.
26.
ATTENTION: Immediately close the air conditioner pipes with plugs to prevent dust and moisture from getting into them.
Disconnect the 2 air conditioning lines from the bulkhead.
- Remove the bolt.
- Remove and discard the O-rings.
27. Remove 2 adapter panels. Unscrew 4 nuts.
28. Disconnect the 3 ground cables from the lower part of the front pillar on the driver's side. Remove the 2 nuts.
29. Disconnect the 5 electrical connectors at the bottom of the A-pillar on the driver's side.
30. Disconnect the 3 ground cables from the lower front pillar on the passenger side. Remove the 2 nuts.
31. Disconnect the 5 electrical connectors at the bottom of the front pillar on the passenger side.
32. Disconnect the heater motor electrical connector.
33. Disconnect the 2 central junction block (CJB) electrical connectors.
34. Disconnect the 2 electrical connectors from the instrument panel center reinforcement.
35. Disconnect the fiber optic cables from the instrument panel center reinforcement if the vehicle is equipped. Disconnect the electrical connector.
36. From the driver's side: remove the Torx head bolt securing the heater housing to the bulkhead.
37. On the passenger side, remove the Torx head bolt securing the heater housing to the bulkhead.
38. With assistance, remove the instrument panel. Remove the 4 Torx head bolts.
Installation
1. Install the instrument cluster with assistance. Tighten the Torx head bolts. (tightening torque 25 Nm).
2. On the passenger side, insert the Torx head bolt securing the heater housing to the bulkhead and tighten. (tightening torque 6 Nm).
3. Driver's side: Install the Torx head bolt securing the heater housing to the bulkhead and tighten. (tightening torque 6 Nm).
4. Connect the fiber optic cables to the instrument panel center reinforcement.
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5. Connect the electrical connectors to the instrument panel center reinforcement.
6. Connect the Central Junction Block (CJB) electrical connectors.
7. Connect the heater motor electrical connector.
8. Connect the electrical connectors at the bottom of the A-pillar on the passenger side.
9. Connect the ground cables to the lower portion of the front pillar on the passenger side. Tighten the nuts. (tightening torque 10 Nm).
10. Connect the electrical connectors at the bottom of the A-pillar on the driver's side.
11. Connect the ground cables to the lower part of the A-pillar on the driver's side. Tighten the nuts. (tightening torque 10 Nm).
12. Install the adapter panels. Tighten the nuts. (tightening torque 10 Nm).
13. Connect the air conditioning system pipes to the bulkhead.
- Clean the parts.
- Install new O-rings.
- Tighten the bolt (tightening torque 10 Nm).
15. Connect the heater hoses to the bulkhead.
16. Install the Torx head bolt securing the instrument panel to the bulkhead and tighten it. (tightening torque 25 Nm).
17. Install the mixing chamber panel. For more information, refer to Accumulating Chamber (80.15.62)
18. Screw in the bolt securing the upper part of the instrument panel to the body and tighten it. (tightening torque 10 Nm).
19. Install the speaker grille. Engage the clips.
20. Install the instrument panel center bracket Torx head bolts and tighten (tightening torque 25 Nm).
21. Install the central heater ducts.
22. Connect the drain tubes to the heater body.
23. Install the intermediate shaft of the steering column. Screw in the special bolt and tighten the new nut. (tightening torque 22 Nm).
24. Install the gear selector lever. Tighten the bolts. (tightening torque 10 Nm).
25. Connect the gear selector lever cable. Install the clamp.
26. Install the front seats. For more information, refer to Front Seat (78.10.44/99)
27. Install the door assembly with assistance.
- Connect the electrical connector.
- Secure the electrical connector.
- Secure the sealing sleeve.
- Tighten the bolts (tightening torque 10 Nm).
29. Install the driver's side trim panel.
- Connect the electrical connector.
- Engage the clamp.
- Tighten the screws.
- Connect the electrical connector.
- Engage the clamp.
- Tighten the screws.
32. Install the floor console. For more information, refer to Floor Console (76.25.01)
33. Fill the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
34. Charge the air conditioning system. For more information, refer to Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (82.30.02)
35. Install the engine cover. For more information, refer to Engine Cover - 4.4L (12.30.50)
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