w BODY 23-1 BODY ‘TABLE OF CONTENTS pace page Boor ‘ULGATE 2 WARNING. FULL D00R 6 SAFETY PRECAUTIONS AND WARNINGS... HALE BOOR 2 STANDARD PROCEDURE EXTERIOR ra STANDARD PROCEDURE - BODY ooo 34 LusRicariOn 1 INSTRUMENT PANEL 36 PANEL REPAR 2 PAINT a SPECIFICATIONS - TORQUE {0 STATIONARY GLASS 7 SPECIAL TOS WEATHERSTRIPISEALS 2 ‘Boo 1s Boy stRucTURE 2% BODY + Do not use harsh sikaline based cleaning 20l- vents on painted or upholstered suraces. Damage {ofinish or color can result WARNING ‘Do net hammer o pound on plat trim pane! SAFETY PRECAUTIONS AND WARNINGS WARNING: USE AN OSHA APPROVED BREATHING FILTER WHEN SPRAVING PAINT OR SOLVENTS IN ‘A-CONFINED “AREA. PERSONAL INJURY CAN RESULT, AVOID PROLONGED SKIN CONTACT WITH SOLVENTS. PERSONAL INJURY CAN RESULT. * D0 NOT STAND UNDER'A HOISTED VEHICLE ‘CAUTION: When holes must be dilled or punched Ivan inner body pane, very depth of space tothe ‘outer body pana, sacrical wiring, of ther compo. ents. Damage to vehicle ean result. +o not weld exterior panels uniess combustible materi on the Interior of vehicle Is removed from the repair are, Fo oF hazardous conditions, can result Always have a fie extinguisher ready for use when welding, Disconnect the negative (cable clamp from the battery when servicing elactrlcal componeats that are ive when the ignition 's OFF. Damage to ‘lctrical systom can recut * Do not use abrasive chemicals or compounds ‘on painted surfaces. Damage to finish can resul when ‘servicing interior tm, Plastic panels can bres STANDARD PROCEDURE ‘STANDARD PROCEDURE - BODY LUBRICATION All mechanisms and linkages shoud be hbricated when necessary. The wll manealn ease of operate ‘Prolong thet ie as well esto tnprove dove sealing, ‘All applicable exterior and inter vehicle operat. ing mechanisms should be inapected and cleaned Drvlstding contact areas Use mechenins should then be Iubreated 1H) When novesary ube the operating eh annie with the specie brant. (2) Apply icane tric toa clath and wie i con doe sels 1 evoid over spray that ‘can soll pos ‘Sergers aching. (3) Belore applying Wbricant, the component Tubrican should be removed (G) The food tate, Int release mechani, latch 1G) The door lack «sliders should bo lubricated tie each Yer (preferably autun ad spring Ine Spray tana a of ak inde Ia23-2 BODY BODY (Continued) + Apply a small amount tothe key and insert Into the lock extnder se unlacked position several es. "Remove the hes. Wipe the lubricant fom with [Component | Fluid, Lubricant, or Genuine Par Rises ooor And | Mopar* Engne OF Hoos Ligate opar® Muti Purpose Lube NLGI Grade 2€P, GAB. oo, opar® Mut. Purpose Lube NLS Hoossaty | Grave 2EP, CCAS fester, cingote Sear Tiopar* Waa Purpone Lube NUT Requstore | Grave 2EP, cous fr [Window | oper Spray Wits Lobe sysiem [Components ry Tapa Lak Cynder Lae JCvindors Parking Brave | Hovar™ Whee! Bg, Grease RUST [Som Top Mopar® Som Top Zipper Gleaner © Lubncant ‘STANDARD PROCEDURE - PLASTIC BODY PANEL REPAIR “There are many lileentsypes of pasts sadn todays attomettve environment: We group plastics in thre diferent categories Rig Semi Rg and Flexible. Any of hese pasties may segue the use of sn adhesin promote for repair Theae peso plas te ae uned extensively on DainlerChysier Motors Ft plane Monica nel eopaie procedures Rigid Plastics: Examples of rigid plastic use: Fasclas, Hoods Daors. sd other Boy Panels. which incude SMC. ABS. and Polyearbonaes. ‘SemiRgid Plastics: Examples of semi rigid paste use: Itariar Panels, Under Hood Panels, and ather Body Trim Panes 1 Flexible Plastics: Moldings, and upper and lower Fascia Covers Repair Procedure: “The repair procedure for all Une calmyories of plastics ip basally the seme. The one illerence fs the material used foc the repae The materils must, see Tread aati re sr Stmirig plasue repatr and flexible repair material for Meible plastic repair ‘Adhesion PromoteriSurtace Modifier: ‘Adhesion PrometeriSurface Modifiers are requied for certain plastics, All three categories may have Plastics thot require the use of adhesion promaer! nfae nmlirs, Always flow eer master betes paste encfiation and. repair procedures ‘SAFETY PRECAUTION AND WARNINGS. WARNING: ‘EYE PROTECTION SHOULD SE USED WHEN ‘CAN RESULT. USE AN OSHA APPROVED BREATHING MASK WHEN MIXING EPOXY, GRINDING, AND SPRAYING PAINT OR SOLVENTS IN A CONFINED AREA. PER: “AVOID PROLONGED SKIN. CONTACT. WITH RESIN, PETROLEUM, OR ALCOHOL BASED SOL- = DO NOT VENTURE UNDER A HOISTED VEH CLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS. "PERSONAL INJURY CAN RESULT. note: ‘+ When holes must be dille or cut in body pan ‘15, verify locations of Internal body components ‘nd electcs! wiring. Damage to vehele can result ' Do net use abrasive chemicals or compounds fon undamaged painted surfaces around. repair ‘reas. Damage to finish can resultw BODY 23-3 BODY (Continued) RIGID, SEML-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES CODE, FAIS NANE ‘CORON TRADE NAME | TYPICAL APPLICATION aS TERVIONTTRICE STYRENE] CORAN'S CONSOLES, GAILES AcRvtTe BUTADIENE STYRENE GRILLES ABSPS | ABSPC ALLOY PULSE, PROLOY, ‘DOORS, NSTRUVENT BRVBLEND, PANELS. RESIS | RESP RLLOY PROLOY, PULSE, LUSTRAN, ] DOOR PANELS, GRULES, cyccovn TRIM Bi BOK MOTOS aue FENDER EXTENSIONS Compound ea ERTVLENE NETH ‘SURYA, EN TONOWER | BUMPER GUARDS, PADS ACRYLATEIONOMER ETTON | wETTON TETTON ‘GRILLES, MOK PANES RUNNING BOARDS PPO WORRED PRO SPOLER ASSEMBLY POLYPHENYLENE OXIDE Pe POLYAMID TEL WOVE, PR FENDERS, GUARTER PANELS HisLon PET THERNOPLASTIC FYNITE Tae Potvesten PaTPPO | PRTPPO ALLOY ER CLRODNES Pare POLYSUTYLENE PBT, PAIR POCAN, VALOX | WHEEL COVERS, FENDERS, THEREPTHALATE GRILLES PaTPEESC | POLYaUTYLENE: BEXIOY WW PETPEESC —] FASCIAS, ROCKER PANEL THEREPTHALATEIEESC MOLONGS ALLow Be POLY CARONATE TEXGN,WERCON, CALIBRE, ] TAI UGHT LENSES IP TRO, MAKROLON PC VALANCE PANELS PORES | POTABS ALLOY ‘GERHAX, BAY BLENDS, | DOORS, NGTRUVENT PULSE PANELS, Pro POLYPRENVLENE ODE | AZOEL, ROSTER, TNTERIOR TRIM DOOR MARLEX PRFAX, NORYL, | PANELS, SPLASH SHIELDS, Grxpro STEERING COLUMN SHROUD [PROTA | POLYPRENYLENET PPOPA GTX BIO FENDERS, QUARTER PANELS POLYAMIO PREV FIBERGLASS RERFORGED | FGERGIAGS, FV PRY | BOOY PANELS Puastic Ps POLYSTTRENE TOSTRER STVRON, PS] DOOR PANELS, BASH PANELS. aa RESIN TRANSFER ar BODY PANELS MOLDING COMPOUND, su ‘SHEET WOLDED SE OGY PANELS CowPouns fe TRANSFER MOLDING [HS “GRULES cowPOUND23-4 BODY BODY (Continued) 1 CODE FAI NANE ‘CORON TRADE NAME | TYPICAL APPLICATION POLYESTER xsi, UP UFTGATES, FLARESIDE (THERWOSETTING) FENDERS, FENDER COPOLYMER [EESGPETP | EEDCPOLYaUTYLENE | EEBG, PATE BEXLOY TOMPER, ROKER PANELS TEREPTHALATE Ener ETHYLENE WODIED | EWP BUMPER COVERS POLYPROPYLENE EPow TEIRYLENED ‘EPDM, NORDEL VSTALON | BUVPERS PROPROPYLENE DIENE PROPROPYLENE CO- POLYMER eu FOAM POLTURETHANE | WPU SPOLERS Pe POLYETHYLENE ‘ALATHON, DYLAN, : Pr POLYPROPYIENE ‘NORV. AZDEL, MARLOX, | NNER FENDER, SPOILERS, (BLENDS) DYLON, PRAVEX Kick PANELS PRIEPGM | PPIEPOM ALLOY PPEPOW SPOLERS, GALES POR POLYURETHANE, ‘COLONELS, FUR PU FASCIAS, SUPERS [PURC | PURPC ALLOY. TEXN BUMPERS Pv POLYVINYL CHLORIDE | APEX, GEON, VRVLITE BODY MOLDINGS. WIRE WnEELs ne REACTION NUEGTED | Ri, BAVFLEX FRONT FSGS, MODULAR MOLDED POLYURETHANE winoows IJECTED MOLDED Booy TRIMS: ABE THERMO POLYETHYLENE | TPE AVTREL, SEXLOV | FASCIAS, BUNPERS, ‘GLADDINGS feo THERNGPOLVOLEFIN | FOLVIROPE, RENFLEX, BUMPERS. END CAPS, ETA, APEX. TPO, SHIELDS, | SIGHT, INTERIOR 8 POST CLADONGS ee THERNO TP BUMPERS POLYPROPYLENE oz TTRERNOPOLYORE THANE] TPU_RYTREL, TEX OMPERS, BOBY SDE, Potvester ESTANE MOLOINGS, FENDERS, PANEL SECTIONING reinforce should be washed, then sanded, Be sure to lie rept st wil be necesary to Feinfrce the pul (Fig. 1. To bond two plastic panels togeller re forcement mst overlap uch panels. The panels wipe off any excess soap and water when finished Tphly si or abrade the paste lth a strane pod or sandpaper Blow ol ny dust with compressed fir oF wipe with ocean dy tog,w BODY (Continued) Fig. 1 PANEL SECTIONING ‘When bonding plastic panels, Follow repair mate Hal manfactrers recommendations. Be sure that ‘ou and ta fill the ull bond line. Once the pieces have been brought gether do nat move them unt ‘Mtr the parts have been bonded and have had ine to cure, rough sand the seam and apply the final Mller with a spreader, wooden tngue depressor. of squeegee. For fine texturing, smell amount of stefan beanie the ier site we Sry ond ay il step cleanup can be done lh Soapy water Wipe the srface clean with a ry doth “lowing timo Fer the panel to dry before moving on PANEL REINFORCEMENT Sa pnp fr il ps wh aching. Reinforcements cat be made il several ‘nplications af glass cloth saturated with stroctaral fachesive. Somirigil or flexible repair materials Should te used for sembright or Mexible backing Torcement (Fig. 2) and Fig. 31. Open meshed ber loss dry all tape “canbe. used. to forma Felnfrcement. The dry wall tae allows the resin (0 the panel and the adhesive Steucturaly. the mare ‘ry wall tape used, the stronger the ropa (Uist i of sa a an be de So pe Sar plese and Bond wh structural adhesive. The BODY 23-5 reinforcement should cover he entire break and ‘Should have o generous amount of everlap on either When repairing plastic, the damage area is frst “Vad out a beveled. Large bonding areas are desi shew ren oti bce al i re srcund a crack ata 20 deyree ange will ease the tonding surface for a repair (Fig. $) It Is rec mended that sharp edges be avoided because the Init enay’ show throaghafer the panel refinished Fig. 2 SOFTENED EDGES Fig, 9 PANEL REINFORCEMENT Fig. 4 BEVELING ANGLE -20 DEGREE23-6 BODY BODY (Continued) + Papel repair for both flexible and rig panels ‘are basieally the same. The primary diference im the adhesive materials used (Fig 9), +The technician sel fist decide what needs to (One should determine i tf posible ty retary the demage pat tos orginal strength ed appearance ‘without excreting the valve of the replacement part "When paste repairs are required, is recor very possible, That wil save time, and the pana Wil remain stationary during the repa: Mislign Trent can couse stress the sepa areas ad an Fig. 5 FIBERGLASS TAPE VISUAL INSPECTION ‘Composite materials can mask the severky of an Carefully to. get-8 true damage assensment Close Inet ay egret er Teentily the type of repair: Puncture or Crack Damage that has penetrated completely through the panel Damage i conf to one general area 8 panel section isnot rite. However backer Patel open fiberglass tape, or mated material ust be bonded fren behind (Fig 7) (Fig. 6, PANEL SURFACE PREPARATION 1 a body pane! has been punctured. cracked, of ‘rushed, the damaged area must be removed fom thee thw cr ea A er be stopped or emeved. To step o running crack in Panel dle Gm (0.280 in. hole ac the end ofthe {rack farthest ven from the damage I sper web ‘focks ean not be stopped, the panel would require Teplocenent. The surfaces arvund the damaged tea ‘ould he stripped of paint and Freed from wos ond ll Seu surfaces around repair area with 300 grit (of repair materials : H 1 7 o Sor Fig. 6 DAMAGE COMPONENT PATCHING PRNELS ‘An pane tha has extensive puncture type damage can be repaired by ctng out the damage materia (Cig. 7) Use a susable elprocating sar or cut oT ‘rhea te sennve the sein a the pel tal da [aged The plece ct ait can be deed a a tempi to hope the om ph I sarc ae Bevel edges of catout at 20 depres to expose a larger Thonn area an the outer side This wil lla for an Increased relforcement areas @ @ = @ , ~ Fig. 7 OAMAGED PANEL. CUTOUT AND PATCH Sofiores na iets PANEL PATCH FABRICATIONS ‘pth can fabricated rom any rig orgs fren, LN gates and fers car ie used 4 supy petch material If existing material is not availabe ‘compatible patch cat be eastruced with adhew BODY (Continued) sive and eenforcement mesh (dry wall tape), Perform the flloing operation If required a) Cover wowed paper or plastic with adhesive Sacked ‘nan mesh ‘ary wall tape) tanger than the patch sequied (Fig. 8 (2) Tape waned paper or laste sheet with nes 0 3) Apply a tieral cost of adhesive ver the sen forcement res (Fig. 8) necessary apply a scand ‘ured. The tiekness ofthe patch should be the same 1s the rep eee. (a) After patch as cured, peel wand pap plastic from the back of the pate, (G) It esied, a thin fin coat of adbesive can be applied ta the bac of the patch to rover mesh for ‘ed strength, @® oO ® =o ‘Fig. 8 FABRICATED PANEL PANEL PATCH INSTALLATION (0) Make @ paper or cardboard pattern the sie and shape of the eatout ble the panel (2) Trim 3 mm (0.125 in) from ep of pattern 50 patch wil have a ep betwoun connecting Surfaces () Using the patern as a gute. cut the patch 1s see {Cut serap pleces of patch materla nt 50 1 (2 in) squares to use path supports to sustain the pote in the cutout {3} Dri tr (0 160) bees 13 mn 05 8) (6) Drill vn (0160 in) aes 13. (08 sn} ‘away from edge of patch aerass from holes dled ‘round eutoue (1) Drill 3 tm (0125 fx) oles tn the suppers Saqares 13 ran (05 in) from he eget the enter tone side BODY 23-7 (8) Scu the backside of the body panel around the ‘tout hole with a sul pad or sandpaper (9) Mix eaugh aesive ta cover one se a al HO) Apply adesive to caver onesie fall support IUD) Using mumber 8 shect metal screws, secure supynrt squares to back side of body panel wath SSdherve sanciviched Reten the panel and squares ig 9) @ Fig. 9 SECURE SUPPORT SQUARES TO BODY PANEL (02) Posidon patch in cutout against suppor squares ana adjust pate unt the gap 6 equal slong, fal sles (Fg. 10) Fig. 10 POSITION PATCH I CUTOUT AND ALIGN23-8 BODY BODY (Continued) 13) Dri 3 mi (0125 in) oles In the suppor squares thraigh the pre driled holes inthe patch, Ua) py # coat of aesive Co the exposed ends ‘tthe support squares (Fig 1) ‘Fig, #1 APPLY ADHESIVE TO SUPPORT SQUARES (15) Inmall serene to hold the patch to suppor souares (Fig. 12) Tighten serews unl patch surface ‘5 Mush with panel Surface f w/ Fig, 12 INSTALL SCREWS (00) Allow adhesive to cure, and remove all sews (07) Using 9 125 man (3 In) 24 pe dle grinder, grind a 50 mm (2 tn) 40.79 mon Cn) wide ad Fn (0.080 In) doep path aera the gaps around the patch (Fig 15). Wh compressed le blow dst fom UB) Apply adhesive becked nylon mesh (dey wal tape) over gaps around path (Fi. 14). 1 U9) Mic enough adhesive to cover the entre patch {20 Apply adhesive over the mesh arvund patch, aun sevoath epoxy with a wide spreader t reduce i Sh grinding. Use two to nee layers af mesh and adhesive to ree stronger reps F413) ) ‘Fg. 18 GRIND SURFACE Fig. 14 COVER GAPS WITH MESH PATCHED PANEL SURFACING te finished using dhe same methods 06 Tnishing father types of toy panels. Th anesb material is ‘aposed in the pated ares grind surlae down ae fpply a coat of high quallty righ plate bod ile Prime, block Sand, and palit as eequiedFig 15 COVER MESH WITH ADHESIVE BODY 23-9 ‘STANDARD PROCEDURE - BUZZ, SQUEAK & RATTLE Buzz, Squeek & Ratios (BSR) may be caused by ‘any one of more ofthe following and may be cor = Lanse fasteners shouldbe tightened to specie ‘Damage ar missing eps shoul be repace. 1 Damaged iim panes seule be replaced. 4 Tecarectly installed teem panels Should be een stalled properly. Many’ BSR complaints sich as lose rim, can be serviced neg the Mopor® Parts BSR Nate Redac tion Ki. This kit contains various tapes chiding Foam, fleck and ont squeak used to eliminate noises ty a components, Refer to dhe Buz, Squeak & Rat tle Kie table for material contents ad usage (BUZZ, SQUEAK & RATTLE KIT TEM FERTURES, “APPLIGRTIONS SERVCE TEMP ich Ara Sauoak rape ‘in xasonresstant male {rn ono 0 conor to most ‘opus sutscee. Stop most Bebveen metal and metal] 40" 225" rot and plate, meta and | Fahenhot “evil ane plat. Interior | (40" to 107° ‘hes and squeaks Examples Tim panels and | Cos) bozo [BEE Rion Flock | Ron Floor wif an aggrasene | Bowwoon rota ana mets | 107 Ta" serve achesve Provaes for” | meta ane pss, vny ane | Fatvenkok Gushonng ana compression, | plastic (oro 2 Cetus) ‘320 leotes components | Example: Pull cps, bozo Wiaterresstant fps, ducts, op ever ass, oul pane. agp Gena Tar essa gh raion | Between meta ara metal [20° Ta" lUretane Feam | and. dab, metal and piste, War Fetrentat resstant (40°10 82° Cetus) Eaenples: I, heavy ret rats. eoting backs [Span Cal Foam | Sok toam conforms w Weguar_| Wee haness and connector | 20" Ta" pe sures wap. Fenner Erarmplos: Soa, gasket, | (40°10 82" Cebus) vweing est duct Densty Foam Tae | restiane Proven losing fuer and | Fehenfer ratlos when apple to deer | (40" to 82 Cobiue) ster Ears: Door, uP23-10 BODY 1 BODY (Continued) Trew FEATURES, “APPLICATIONS ‘SERVICE TEMP INVE* Grasse B90 —| Ung ‘Suspeions or 380" Exaples: Sixt busigs, easy | Fabronhot bars (40°10 200° aioe OT Tang We WHT at ay autor | When access snot possbie, ot | 20" 400" ham plats or rubber. wit migrate to condition Vin | Febrenhet rubber past, meta, (Ber 10 205° Examples Converbie top | Cals) bush p eos tm net Rofo Grasse | Lang We Wilt ay autor | Vinyl rubber, paste metal — | AO ‘nem plats or robber. gis Fomennot Examples: Weatherstios, | (34°10 205" bnckie ans winganela asus) mmoiinge. ‘SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION Tm Fi lbe: Trobe, Bay sce guardide BOTS a 7 rc Bis auc tO 7 7 Hood asst sping bl z = B ood ath ms 7 = death bracket ra 7 7 = Feed fige sews 2a 2 = ood safety atch bot 2 = = Docket eat ror anchor bal a7 Ea = ‘Bucket soa ear aboard anchor Bar 7 3 = Ligate glass bat sto nat = 0 = ‘Lungate gas hinge nat . = = Tate tinge to Parton om 7 7 3 Fron fring fap ba a a5 = Fron reactor to a = = Rear uring oop bot a = = Rear ba anchor Bok a = = Rear ior at em 7 7 7 ear bw archer bat = = = Si support barf sport bar Bae 2 7 = Side suppor sport bar fo winehiee Fee Boe = 2 Spor bor bracket bok & 30 = “Spt bar saa pod bats = 3 =w sODY 23-11 BODY (Continued) DESCRIPTION on Fie Tete Sper bar fo west cuss baie 2 0 = Spar batt cargo or Bats o 0 = Taig Hinge arewe 7 = Taigate seer 7 = = SPECIAL TOOLS Booby23-12 TAILGATE 1 TAILGATE TABLE OF CONTENTS pee page ‘TAILGATE OUTSIDE HANDLE INSTALLATION “ REMOVAL 12 UPTGATE GLASS WEATHERSTRIP ‘TAILGATE HINGE ‘TAILGATE LOCK CvLINDER REMOVAL 12 “REMOVAL “ INSTALLATION 32 INSTALLATION “ ‘TAILGATE LATCH LIFTGATE GLASS SUPPORT CYLINDER REMOVAL sa REMOVAL 6 INSTALLATION 33 _ INSTALLATION 6 REMOVAL 33 "REMOVAL 1s INSTALLATION 13 INSTALLANON 6 LUPTGATE GLASS HINGE OUSTIENTS REMOVAL ss“ ADJUSTMENT 6 UFTGATE GLASS REMOVAL “ TAILGATE OUTSIDE HANDLE _ INSTALLATION (1) Pasion the set an auside release hana on REMOVAL the tailgate. end install screws 1) Remove the fateh trom che tailgate Reler to 28 - BODVTAILGATEILATCH - REMOVAL) (@) Rem the screws ataching the outside han ate to the tailgate (Fg) (G) Seporate the eutaide handle apd seal fom the taza Fig. # TAILGATE OUTSIDE HANDLE (2) Install the screws sttaching the outside Randle (3) stall the latch. (Refer to 28 - BODYITAIL GATEMLATCH " INSTALLATION) TAILGATE HINGE REMOVAL, NOTE: Hinges may be serviced individual f both fre to be serviced, remevelinstall hinges one | time. 0) Using a grease penlt or equvtent, mark the peste af the hinge on he bod (2) Remave the screws attaching the hinge to the ‘dy and eatlgate (i 21 (8) Separate the hire fram the tailgate INSTALLATION NOTE: Hinges may be serviced individual Wf both fare to be Serviced, remavelinstal hinges one (0) Prepare and paint the replacement nge tow ‘TAILGATE HINGE (Continued) Fig. 2 TAILGATE HINGE (2) Lubricate the hinge with spray Inbrcant (3) Align and pnition Une hinge tthe bay snd top (4) stall the serews and ugh the seraws co 23, mv 200 in. Ibe) TAILGATE LATCH REMOVAL (1) Open che tailgate and remove che Lteh im cover Pi. 3 (2) Disconnect the outside han to Itch od (5) Disconnect the lc elder to latch rad (4) Reroove dhe sce attaching atch to tallgate (6) Separate the Tat from the INSTALLATION (Q) Poston che latch in the tigate, (2) ntl the screw alcating lath to tallgate, Do ot tighten sere (3) Conner the lock eyiner t latch eo (4) Connect the outside Pande lote rd (9) Install the late tei cover. Tighten al serve TAILGATE LATCH STRIKER REMOVAL (U) Rernive the striker frm the bracket. (2) Rermove the shirm washers fromm the bracket. () Remus the screws attaching the strker INSTALLATION (1) Pesta the striker bracket on the bay and THILGATE 2.8 (2) Poston the striker and shim washers on the sariker bracket. (3) stall the striker in the bracket ana tighten the striker to TL Nim (52 1 Ths) LIFTGATE GLASS HINGE REMOVAL 1) Open tage (2) Open and support hityace las (3) Remave wiper motor cover right hinge ony). (Refer to 3 - ELECTRICALTEAR WIPERSMASH. REMOVAL) [al Remove dhe wiper blade. Refer te 8 - ELEC ‘TRICALREAR. WIPERSWWASHERSREAR WIPER BLADE” REMOVAL) (5) Remove the nut attaching the gate hinge 16 the liga glass (6) Mark the poston of the hinge inthe top and a) INSTALLATION (0) Align and position the hinge on the top and (2) Install the nut attaching the htgate hinge to the ligate glass and tighten to 6 Non (3 in Tbs} {s) nstll wiper motor cover Reer ta 8 ELEC. ‘TRICALIREAR WIPERSIWASHERSIREAR WIPER MOTOR TRIM COVER - INSTALLATION)23-14 TAILGATE LIFTGATE GLASS HINGE (Continued) (4) stall the wiper blade, (Refer wo 8 ELECTR CALREAR. | WIPERSWASHERSREAR WIPER BLADE - INSTALLATION) LIFTGATE GLASS REMOVAL (a) Disemace dhe var dafester harness canoer. (2) Dissomet the per motor harness connectors PORT RODS WITH THE LIFTGATE CLOSED. THE SUPPORT ROD PISTONS ARE OPERATED BY HIGH PRESSURE GAS AND COULD CAUSE. PERSONAL INJURY ANDIOR VEHICLE DAMAGE IF THEY ARE REMOVED WITH. THE PISTONS COMPRESSED (UFTGATE CLOSED), ONCE REMOVED, DO NOT [ATTEMPT TO DISASSENGLE OR REPAIR THE SUP- (3) Open the tatigate ond hitgate (@) Remove support ral lets. Refer wo 23 ODY/TAILGATHSUPPORT CYLINDER = REMOVAL) (9) Remove the bots staching the Late hire the hardtop (Fig. 5) (6) Separate the litgate glass from the hard tp. INSTALLATION fe all related commoner, we istll support rd ball stds ene tighten the mut to 12 Nim (12 In. Is (2) Pesan he figate glass at Use ard op (3) Install the bolts attarhing the liga hinge to the harap and tighten to 10 Nm (05 nbs, 1 Fig, 8 LFTGATE GLASS (a) Install dhe support roe endorser to 23 BODYITAILGATESUPPORT CYLINDER = INSTALLA. TION) LIFTGATE GLASS WEATHERSTRIP DESCRIPTION ‘The Wgate glass weatherstrip s attached tothe Iiggate lass and fe not servleable I the Mgate floss neatherstrip needs tobe replaced, replace the Hitgate plas. eter to. 23” BODVILIPTGATE GLASS REMOVAL) TAILGATE LOCK CYLINDER REMOVAL 11) Ope the titgats (2) Remove the latch cover. (3) Remave the lek cyder retainer clip, (a) Remove the lak cyder fom the taligate INSTALLATION 1) Paxton the nck eller ts tho algae ogo, (2) Comet he ln einer to lath fod (3) Install the lack eginder real lip, (a) Install the Inch coverw LIFTGATE GLASS SUPPORT CYLINDER REMOVAL WARNING: DO NOT REMOVE THE LIFTGATE SUP- PORT RODS. WITH THE LIFTGATE CLOSED. THE SUPPORT ROD PISTONS ARE OPERATED BY HIGH PRESSURE GAS AND COULD CAUSE PERSONAL IRUURY ANDIOR VEHICLE DAMAGE IF THEY ARE REMOVED WITH THE PISTONS COMPRESSED (LIFT. GGATE CLOSED). ONCE REMOVED, 00 NOT ATTEMPT ‘TO DISASSENBLE OR REPAIR THE SUPPORT RODS. (0) Open and suppoce the Utgate glass (2) Relense the anpprt rd einer retaining lips ‘ax bet ends of each support rod cling Fig 6) (2) Pll the support rod off the Ball stu Fi. 7. _—— GF TO ee ee 78 SuppoRT ROD CYLNDER CoHNecTION Fig. 7 SUPPORT ROD CYLINDER REMOVAL THILGATE 23-15, INSTALLATION 1) Pole the supa sod eytnders oe bal sta (2 Install the support rod evinder retainer clips TAILGATE REMOVAL (1) Remave dhe spare te. (2) Open the tage ane remove the center high rnaunted stp lan CHMSL) contact caver (ig 8) {31 Disengoge the CHMSL elec connectors sll Roar ino at ack the tte 3) Separate te tagate om dhe vie Fig. 8 CHMSL CONTACT COVER INSTALLATION NOTE: 1 necessary transfer tl related compo- 0) stall the screws that attach the taligate 12) Enpage dhe CHM. electrical connects (3) Install the CHMSL contact cover (4) Close the tailgate an install the spare tite ADJUSTMENTS ‘ADJUSTMENT (1) Lanse the tllgate hinges body screws (2) Al the tage tn they opening and Lighten the hinge screws. Refer to 23 BODY'BODY STRUCTUREIGAP AND. FLUSH SPECIFICA TIONS)23-16 FULL DOOR 1 FULL DOOR ‘TABLE OF CONTENTS pee page oor INSTALLATION 1° REMOVAL 436 INSIDE HANDLE ACTUATOR ADJUSTMENTS INSTALLATION 2D "ADJUSTMENT 16 LATCH. ooR GLASS: REMOVAL ~» REMOVAL 46 INSTALLATION 2 INSTALLATION {LATCH STRIKER WINDOW REGULATOR REWOVAL ~» INSTALLATION 4F Lock evuNDER EXTERIOR HANDLE REMOVAL 2 REMOVAL 17 _ INSTALLATION a INSTALLATION 38 TRIM PANEL REMOVAL 48 INSTALLATION 2 INSTALLATION ° ince REMOVAL 9 DOoR INSTALLATION (0) Postion the door in the hinge ond install the REMOVAL suis (1) Open the door (2) Disconnect the door restraint strap fram the in (Fig 3) Rermmue the nuts atthe door hinge pivots and ltt the dooe from the body: Fig, 1 RESTRAINT STRAP (2) Connect the door restraint strap atthe pin ADJUSTMENTS ‘ADJUSTMENT he dare ean ot he ig tachi oe {nd ti adjustments Enlarged holes are also Tocted In the door fupper and lower Hinges) for up, dwn, fore, aft ana tt schists Prise to daor adjustment or aligrment, the door latch rnust be removed to alaw the door to clase Freely and be properly alane “The der laich striker should be adjusted in ar out to all the dor lac tobe fully engaged. The door ‘Should be flush with the adjacent body panes DOOR GLASS REMOVAL (U) Remave the doar tri pane and Use waterdar (Reler to-23- BODVIFULL DOORTRIM PANEL REMOVAL).w DOOR GLASS (Continued) (2) Pull the door glass run channel fram the door sal (3) Rol lass fly dowrwar @) Using ate tick “C4755 or equivalent remove the screws etd reste the dou ae panel (Fig 2) ara (Fg 3), (5) Rell glass Lt upward to access eegulater arm (0) Remove the scows that atsch the regulator ari gulde tothe glass (7 Lit te glass upward while le, tere ane Fig, 2 DOOR SAIL SCREWS Fig, DOOR SAIL REMOVAL INSTALLATION (1) Posi the glass the doe emuring the 1a 6 aligned inthe lass un chan FULL DOOR 23-17 (2) Install the screws that attach the segulator ‘arin guide othe glass, {31 stall the dor sail pane (a) Install the ru chonnel tthe dor sai. (5) install the waterdanr and the door trian panel (Refer to 25." BODYIFULL. DOORTRIM PANEL INSTALLATION WINDOW REGULATOR REMOVAL (U) Remave door glass (Refer DOOR/DOOR GIASS - REMOVAL) (2) Loowen the tots inthe sltted holes (Fi. (3) Remove the bols atic the regulator tothe ‘ar inner pa. TL aor wpe fi fom te (9) Laver the regulator and remove i hraugh the ‘access hole inthe door ner panel TF. 8). 23 - BODYIFULL, Fig, 4 WINDOW REGULATOR BOLTS INSTALLATION (0) Position the regular in the dor. (2) Align regulator bats into slot ots. (3) Install elts attaching regulator to the Inner 1a) Tighten the bots tn the slated hates (5) Install dor glass. (eer to 23 - BODYIFULL, DOORIDOOR GLASS = INSTALLATION) EXTERIOR HANDLE REMOVAL (i) Remave che dor trim panel. Reler wa 23, BODY/FULL DOOR/TRIM PANEL - REMOVAL)23-18 FULL DOOR EXTERIOR HANDLE (Continued) Fig. 5 REGULATOR REMOVAL (2) Poston the window in the full upward post 3) Remove the grab handle spent bracket (Fig o. (f) Peet ack the waterdam from dhe door inner panel to access the dor lat 18) Disconnect fram the late, the inside Tek kno to latch rate, the outside release handle to latch 16) Disengage (7) Using ng Nat Bade, tap the handle keepers upward and remove ram the door handle (Fig 7). (8) Remove the lah release rod fom the daar handle (@) Separate the handle nd gaskat from the door INSTALLATION (0) Engage the latch release rad t0 the door han te (2) Peston the gasket and handle tn he door (5) Slide the keepers int the dear handle rm the Ta) Lower the window (8) Using a tong fla bade, tightly tap the handle heepers deetward to secure te nde The ta of te retainer must be positioned on the 2nd oF 3rd ‘tp from the bottam an the handle Keeper, the outside release handle to latch ro (s) Reposition the waterdann (9) tonal the grab handle support bracket. (UO) Tastall the door trim panel. (Reler to 23 BODYIFULL DOOR'TRIM PANEL = INSTALL. TION) 1 Fig. 6 GRAB HANDLE SUPPORT BRACKET Fig. 7 OUTSIDE DOOR HANDLE REMOVAL GLASS RUN CHANNEL REMOVAL (1) Lower the wind (2) Using a trim stick C-4755 or equvatent, car now opening rae :w GLASS RUN CHANNEL (Continued) (3) Remove the door glas. (Refer to 23 FULL DOORIDOOR GLASS - REMOVAL) (@) Grasp the pss run channel weathers i the doe (Fig 8) dd pl frm the chanel BoDv! ‘Fg. 8 FULL DOOR GLASS RUN CHANNEL WEATHERSTRIP INSTALLATION NOTE: Applying 2 mall amount of lubeicant to the ‘weatherstip may ease the Installation (1) Poston the weetherstap in the tower door ‘annals ond press ino pace. (2) Install the door plans. (Refer tp 23 - BODY! FULL DOORDOOR GLASS - INSTALLATION) {G) Pasion the weatherstep Inthe wiedes open Ing ame and press ino place NOTE: Ensure that he glass seated propery Improperly seated door glass will result In: high ‘lass rolhupiolldown effort HINGE REMOVAL (0) Renee the door (Refer to 25 DOORIDOOR - REMOVAL) (2) Using a grease penal or equivalent. mark the ution he xg gro he hay a he ne ‘al Remove the mut trim the upper binge pl 9) FULL DOOR 23-19 NOTE: When removing the door or hinge DO NOT iseard the plese shims or the hinge pi. (4) Remove the igeswbody screws and the hingerdoor screws. Remove the hinge fram the ‘ear and body. Support the dor as necessary The Up hinge fs tegrated withthe endshie hinge Wien removing ity support the windshield trate stab an aggrepriate device pice to roma S Fig. 9 FULL DOOR HINGE INSTALLATION 1) ian he earn ge wh a po (2) Pais the fire co matt the vehicle body: (8) Labricate dhe hunge with spray ubeicans (a) Pasion the hinge onthe toot. align carefully {6| Poston the hinge on the vehicle body. Align the wae pencil marke installation alignment refer. cee marke Intl the seve (6) Install the dur) (Reer to 23 DOOR/DGOR = INSTALLATION) (7) Inspect the windshield allgyment after hinge TS) spect the doar alignment and adjust. ine cssary. Refer tp 28.» BODYIFULL DOORDOOR ADJUSTMENTS) BODYFULL INSIDE HANDLE ACTUATOR REMOVAL (0) Remave the tnx screw ait handle to the door (2) Carell pall dhe handle from the do23-20 FULL DOOR INSIDE HANDLE ACTUATOR (Continued) (9) Disconnect the latch rods from the handle ig. 10) Fig, 10 INSIDE HANDLE ACTUATOR INSTALLATION (2 Position handle and sel dor {Install etre screw attaching the tse han LATCH REMOVAL U) Remove trim pane. Refer to 23 - BODYIFULL, DOOR/TRIM PANEL» REMOVAL) (2) Ral widow to full upward position (3) Discomect" the lock eylinder latch rod, Fig. 10) {Disconnect the tok kn catch ro (5) Disconnect the outside hondle to latch release 16) Remove the screws attaching the Iatch to the oon 17) Laver the ath tthe door an Alsen the inside handle to late ud (8) Remove the Tat fam the dove INSTALLATION (0) Post he ttc nthe door: (2) Connect the inside bande to latch ro (3) Install the seems atacing the latch to the ‘d) Poston the door weachersrip In place, apply adhesive as necessary (3) Conner the autsde Pande to latch rad 1 Fig. 11 DOOR LATCH ASSEMBLY (6) Comme dhe lock Krab to late ri {0} Connect the lok eyiner to atch eo (8) Install erm panel, (Refer to 23 - BODYIFULL, DOORTRIM PANEL” INSTALLATION) LATCH STRIKER REMOVAL (u)Remave the screws attaching the striker tothe at (2) Separate the striker and the spacer from the aay (Fi 12) Fie, LATCH STRIKERw LATCH STRIKER (Continued) INSTALLATION (0) Peston the striker and the spacer on the by (2) install the screws attocking the striker and spacer ta the body. LOCK CYLINDER REMOVAL (0) Renee tr pane. Refer ta 23 - BODYIFULL DOOR/TRIM PANEL - REMOVAL) (2) Peel back watedam. (5) DiscomretTack cylinder to Inch rd (a) Rem lock eyinder retaining lip. (5) Remove he hk lider trom the dase INSTALLATION (0) Hasta the tak evn ithe door (2) Install lock ender retaining clip {31 Connect lock eylindr to Tat ee (a) Secure te water ts the das (5) Intl tri panel. Refer to 28.” BODVIFULL, DOORILOCK CYLINDER = INSTALLATION) TRIM PANEL REMOVAL (U) Lswee the wed (2) Remove the clip attaching the winds lass regular handle to the reyulatac Remove the ham (3) Remove the sere attaching trim panel to vor (Fig 13) 1G) Using "a special tot C4820 or equivalent remove pase-ln Testeners-ataching trim panel to FULL DOOR 23-21 (5) Lit he crim penel upward end separate the teim ponet fom the door Fig 13 FULL INSTALLATION (0) Poston the erm panel on the door: (2) Press the piminTascners attaching. tim (3) Install the screws attaching trim panel ta dae (4) Poston the lip on regulator handle and23-22 HALF DOOR 1 HALF DOOR TABLE OF CONTENTS pee pa9e oor INSTALLATION 2 REMOVAL 2 uaTcH winpow INSTALLATION 2 REMOVAL 22 LATCH STRIKER INSTALLATION 2 “REvovAL, 2 EXTERIOR HANDLE, INSTALLATION oy REMOVAL 22 LOCK CYLINDER INSTALLATION Zs “Revoval ~ DESCRIPTION. 20 TRIM PANEL. INSIDE HANDLE ACTUATOR REMOVAL 2 REMOVAL 23 INSTALLATION % DOOR WINDOW REMOVAL REMOVAL (0) Opes the doe (2) Disconnect the door restraint strap fram the pin Fig Dh 13) Remove the mts atthe door hinge plots and Fig, 4 RESTRAINT STRAP INSTALLATION (0) Poston the door in the hinge and install the 12) Connect the dor restraint strap atthe pin (3) Check for proper eperation {t) Oper de door (2) Grasp the window at both front anid rear edges ‘ond nly upward ig 2 Fig. 2 HALF WINDOW INSTALLATION (U)Staring at the most forward allgment plnw EXTERIOR HANDLE REMOVAL (0) Remove trim pane. (Refer to 25 - BODYIALP OORITRIM PANEL - REMOVAL) 12) Disconnect the cutside hance to latch red (3) Remove screws attaching the outside handle to (a) Seporate the ouside handle apd seal fom the INSTALLATION (1) Posilon the guise handle and seal a the (2 Install screws attaching the ouside handle to (3) Connect che outside handle tp lath rod (4) nscall wim panel. (Refer to 23 BODVIBALE DOOR/TRIM PANEL INSTALLATION) HINGE DESCRIPTION “The servic procedures for the half doe hinge are te Same os the fll dor hinge. (Refer to 23 - BODY! FULL DOORIINGE » REMOVAL) and (Refer to 23 BODVIPULL DOORHINGE INSTALLATION), HALF DOOR 23-23, INSIDE HANDLE ACTUATOR REMOVAL 0) Remove the tore serew attaching the Inside (2) Carefully pall Randle from door (9) Disconnect the latch ras fom the handle Fig 3 ‘Fig, 3 INSIDE HANOLE ACTUATOR INSTALLATION (1) Comme she ltch rods vo the handle (2) Posidon handle an seal In dr (3) tall tne tary sere attaching the inside ban le the to dr23-24 HALF DOOR LATCH REMOVAL (0) Remove trim pane. (Refer to 25 - BODYIALP OORITRIM PANEL " REMOVAL) (2) Disconnect the tek eylinder 0 latch rod ig. 4) (3) Disconnect te lok Kb 0 latch rod (a) Discomt the outside hale to Itch rod (9) Using a tim stick ar equivalent, py back the or weatherstrp ot the fateh to access the screw attaching the latch to the dear (6) Remove the screws ata oor Fig 8) 7) Laer the latch tn the door and disconnect the V8) Rene the lath fram the dor INSTALLATION (1) Pesta the Itch nthe dor: (2) Connect the iside handle to latch rod (3) ncall the screws etacing the latch to the oor ANG) Pesan te dae weathers plc, apt (9) Connect the autsie handle tp latch rd, (6) Connect the lock knob to latch re (1 Conner the lock evinder atch ro (Fig. 4 (3) ostal in panel (Refer to 23 BODYINAL DOORITRIM PANEL» INSTALLATION) 1 Fig. DOOR LATCH LATCH STRIKER REMOVAL (0) Remave the serews attaching the striker tothe 12) Separate the striker and the spacer fFom the body (Fig 8 Fig. 6 LATCH STRIKER INSTALLATION (0) Poston the striker and the spacer on the bay. (2) ntall the screws attaching the striker andw HALF DOOR 23-25 LOCK CYLINDER TRIM PANEL REMOVAL REMOVAL 0) Remove trim pane. (Refer to 25 - BODYIHALP (1) Remove haf door window: (Refer to 23 BODY! OORITRIM PANEL " REMOVAL) (2) Disconnect lock cylinder «biatch rod (Fi. 4 (3) Remove lock cylinder retaining lip. (a) Remon the hk cer Tmt the doe INSTALLATION (1) tall the lok evn inthe door (2) ntl! lack elinder retaining clip (5) Connee ook eyes wo ach ee (4) nstall wi panel (Refer to 23 BODVIBALE DOOR/TRIM PANEL” INSTALLATION) HALF DOORAWINDOW = REMOVAL) (2) Rotate window retainer sleeves 90°, Using a ‘im stk C4735 ar equlvalent, pry sleve reainers (3) Remave the screws attaching trim panel to oer 1G) Using a trim sk C4829 or equivalent renee phn ont, panel 18) Separate the tm panel from the door. INSTALLATION 1) Poston the im panel on the doe (2) Press the pushin fasteners ataching. wim panel to door tne place {3} Install the screws attaching tren panel to dar (a) Posidon retainer sleeves nig door, Raale retainer sleeves 0" to secure Into place (G) install half door window, (Refer to 23 - BODY! HALF DOORWINDOW = INSTALLATION)23-26 EXTERIOR 1 EXTERIOR ‘TABLE OF CONTENTS pee page Boy oEcALs \WHEELHOUSE SPLASH SHIELD DESCRIPTION 25 "REMOVAL 0 INSTALLATION 26 SIDE VIEW MIRROR ‘COWL GRILLE AND SCREEN REMOVAL ot REMOVAL 21 _ INSTALLATION 3 INSTALLATION 2F sie sree RIGHT FRONT FENDER REMOVAL ot REMOVAL 2tNSTALLATION, 3 LEFT FRONT FENDER REMOVAL 2 REMOVAL 28 _ INSTALLATION 2 INSTALLATION 28 ExHAUSTER RADIATOR GRILLE PANEL REMOVAL 2 INSTALLATION 29 BODY SIDE GUARD LICENSE PLATE BRACKET REMOVAL 2 REMOVAL 20 INSTALLATION 3 INSTALLATION 2 BODY DECALS INSTALLATION (0) The area thot wil be covered by the decal mu DESCRIPTION ‘TH decals are durable tape decals with a adhesive beocking "To eliminate Misters and sir bubbles in & decal perce them with e needle ae pin. Force the trapped frost of the hale. as an regulates in dees REMOVAL NOTE: The key to successful decal removal Is to 3 te ae and slowly pool the decal rom (0) Clean the surace as necessary (2) Place a piece uf mashing tape above or bekw the decal a8 reference marke (3) Start ot one end of the decal and apply heat by paling back Do not pull the decal gucwaed fom the pat residue paint Freshly pointed surfaces mast be thr ‘oughly dy (2) Clean patted surface witha commercial wan and sllcane removed solution. Wipe surface with ‘dean clath and allow to dy. (3) Poston decal and carrier on pane and hold i Inplace with pleces masking tape (Gy Lit the bacoa ee ofthe decal and carver use the tape sections as hinges, and reverse the pst tom of the decal and carrer ‘CAUTION: Always remove the cari from the tape ‘Strpeldecal, never remove the tape srpeldecal from the carrer (6) Bend corner ofthe carrer ward, separate 16) Using the making te an the bedy panel align the deca (7) Separate the carrier From one end of the deca (8) Hold tape decal firmly gsi the panel sar foce while seporeting the career from the de 10) Tnpect tape decal with reflected ight to check for defects that could have developed daring the Installation process Remove all ai andor mature ten,w COWL GRILLE AND SCREEN REMOVAL (0) Open the Rood and remove the screws that acta the cow gil and screen to the cow! Fg (@) Remove the gil end soon fram the cow Fig. 1 COWL GRILLE AND SCREEN INSTALLATION NOTE: When instaling the cow! gril, ensure the ‘snorkels onthe cow! are positioned correctly and in ‘Good condition. Msalgned or camaged Seals may ‘ow water to enter the HEVAC, (0) Poston dhe cow! seron and gre on the eve (2) inal the serene that atach dhe lle nd RIGHT FRONT FENDER REMOVAL (U) Remove the battery tray. (Refer to ELEC. ‘TRICALIBATTERY SYSTEMTRAY ~ REMOVAL) (2) Remon the ae eeaner housing, (3) Remove the bots attaching the Power Distrib tion Center (PDC) tothe fender. 1) Disengape the PDC vite harness retainers 0 te bottery tray and fender {51 Move and secure the FDC. ll arama he hgh peste ae condoning EXTERIOR 23-27 (7) Disengage the frant end lighting wire harness retainers on he fender (8) Disengage the balery temperature ses 10) Disengage the vacuum line at Ue reservoir under the battery tray reinforcement bracket U0) Disengoge the headlamp wire commer (01) Route the fog lamp Gf equipped). park lamp ‘and side marker wire harness throwgh the acess oe in the fever el (121 I equipped, remove the Feder flare exten 113) Remove the bolts attaching the fender co the co ig 21 Us) Rennave the bolts attaching the fend co the tery try reinforcement bracket U5) Remove the bots attaching the fender ro the rile U5) Separate the fener rom the vee. INSTALLATION ‘Transfer all related companents. Replace harness {1} Pasion the fender othe vehicle (2) tall the ts attaching the Tender to the (3) stall the ts attaching the fender 16 the battery tay rinforeement bracket (a) Install the bats attaching the fender to the 13) It equipped, install the fender Mare extension ‘and body side molding (0) Rowe the fog lamp f equipped. park lamp and side marker wire harness through the acres Tale inthe Feder well, Set the gromet (7) Engage the headlamp wire connecter (6) Engage the batery temperature sensor cone (0) Engage the vacuum line at the reservoir under the boiey Lay reinforcement bracket (U0) Posi the Trt end lighting wire harness (1 Position he high pressure aie condidening line inthe retainer on the fender. Engage he (12) Poston the PDC on ie Fender ae ns the tots (U5) Posidon the PDC wire hamess into the setainers ante fender and battery tay Engage the (Ud) Install the et ceaner housing (U3) ital the battery tray [Ree to 8 ELEC ‘TRICALBATTERY” SYSTEM/TRAY INSTALLA, TION)23-28 EXTERIOR RIGHT FRONT FENDER (Continued) 1 Fig, 2 FRONT FENDER LEFT FRONT FENDER REMOVAL (1) Disconnect the negative termina on te ba tet Refer to 8 ELECTRICALIBATTERY SYSTEM ENDLES " REMOVAL (2) Remove the wins! washer reser {Remove hor (eer to 8 ELECTRICAL’ HORNIORN - REMOVAL) (@) Remove EVAP easter: {8} Remove the Bolts attaching the ABS Hydraute ‘Contra Unt (HCL) to the mane oy. 1G) Secure the HCU. 1) Remove the HCU cay {Diver the trast ed lighting wire harness ) Disengge the healanp wire connector {10) Rowe Ue fog amp i equipped. park lamp ike inthe er wel : {it Remove te bls attaching the fer tothe cowl (Fig 3 {12} Remove the bits attaching the ferro the 19) Remave the bots attaching the fender co the MUM) Separate the fender rom the veil INSTALLATION “ronsler all related companents, Replace harness reainers damaged {1 Poston he fender onthe vehicle (2) Install the bts attaching the Tender to the (3) Poston the front end lighting wire harness Into the retainers onthe fender Engage the etalners (a) stall the bolts attaching the fender 16 the HU rey reinforcement bracket (Insta the bats attaching the fender to the 16) Mequlpped, itll the body side molding (7) Route the fog lamp if equipped, park lamp fond side marker wire harness through the acess 8) Engage the headlamp wire conmecte: (0) Install the HCU way Uo) Positan the HICUT on the spear eray andw LEFT FRONT FENDER (Continued) EXTERIOR 23-29 Fig, 3 FRONT FENDER (11) Install EVAP canister (02) fasta ors (Refer wo 8 HORNHOEN - INSTALLATION) (03) Engage horn wire connectors. (1a) tal the windshield waster reserve (05) Connect the negative terminal othe batter: (Reler 8 ELECTRICAL/BATTERY SYSTEMICA BLES - INSTALLATION) RADIATOR GRILLE PANEL REMOVAL (u) Rene the front crssmember cover. (2) Remove the eraser valence ever (3) Rete the radiata overfow bottle (@) Remmve the bate that attach the radiator and shroud frome the gle panel (IFAC equipped {a} Evocvate the syst, {0} Disconnect the igh and Tow pressure tines 6) Cover (cap) the lines to prevent (0) Remove the bolts attaching the radiator sup 7) Disconet the heed lamp. car signal, marker lap and horn wire harness conneeers (8) Remave the bots attaching the fenders to the (0) Remove the bolt attaching the geile to the frame mount U0) Separate the grille fom the vehicle. INSTALLATION “Transfer all related component (0) Pasion the pile pret on the vehicle. Ensure the ruber supaort bumpers ate aligned (Fi). (2) nstall Une boll attaching Une pile the Frame (3) lnstall dhe bolts attaching the fenders ca the slept {4} Connect he heed lamp, turn signet, marker lamp and horn wire harness connectors (3) intl the tls attaehing the radiator support ade ca the grille panel 16) IPC eyulpped (a) Connect the high and low pressure lines at tne quick disconnect couplings.23-30 EXTERIOR RADIATOR GRILLE PANEL (Continued) (0) Evoeuate and charge the sytem. (1) Install the rodator and shroud to the grille (3) stall the eodiatr oerow tote (@) Install the cossmenier valence cover. (10) Tata the fron ersomember caer Fig, 4 GRILLE BUMPERS LICENSE PLATE BRACKET REMOVAL (0) restated, remove the teense pate 2) Retmnue ie screws atoching the lense plate bracket to the body (Fh 8) () Separate the braket trom the bay INSTALLATION (0) Poston the bracket on the body (2) Install the screws attaching the Neense plate 13) removed, Istll the lcense plate, WHEELHOUSE SPLASH SHIELD REMOVAL (0) Remove the plasle push pins thot attach the splash shield tothe weethase (iy 5) (2) Remove the pushin fasteners aiteching the splanh shield cathe wheelbase. (Tie pun faster (is are molded inte the splash shel 1 od % oo INSTALLATION (1) Poston the splash shield in che whectheuse. (2) Press the spl shield putin fasteners ito place (3) Attach the splash shield to the whrethousew SIDE VIEW MIRROR REMOVAL (0) Remove the serews attaching the miro tothe oat binge (Fig. 1) 12) Remove the marror fom the door hinge, Fig, 7 Side View mirror INSTALLATION (0) Chen the door Hg mire Base enter "@) Pollan the miro bse atte dor hinge Una tne scr: acing be woe eo the ate hinge EXTERIOR 23-31, SIDE STEP REMOVAL U} Remove the bole that attach the se step to ine frame ig. 8 (2) Tit the step down and disengage the tabs from the frame slots Fig. SIDE STEP INSTALLATION (1) Posidon the site step on tw frame and engage the moaning tbs tna the fame sis (2) stall the bt that attach the side step tothe frame sid tighten to 21 Nom (13 fs)23-32 EXTERIOR WHEEL OPENING FLARE MOLDING REMOVAL A) Remove the skde marker lamp, (Refer to 8 MARKER LAMP UNIT - REMOVAL) (2) Rermove the screws that attach the Mare tothe front fender or rear wheelhouse (ig. 9 (3) Separate the Mare Irom the be: INSTALLATION (Q) Clean he contact surface on the bly tian iC othe frog fener or wheelhouse (G) Insall he screws attaching the Mares ¢o the (a) removed, itll the side marker bap, 1 EXHAUSTER REMOVAL (1) Remove the spre tie {2} Using a tri stick C1785 ar equivalent, spe rate the exhauster from the (alge Fig, 10 BODY EXHAUSTER e "Fig. 8 FENDER FLARESw INSTALLATION (1) Install the exhauster an sea Ft (2) nscll the spare ie BODY SIDE GUARD REMOVAL (A) Rernive the bots frm the Tower support tabs 10, Fig. 1 SIDE GUARD - LOWER EXHAUSTER (Continued) EXTERIOR 23-33 (2) Remove the side bolts and remave the side sand. (Fig 12) Fig, 12 SIDE GUARD - UPPER INSTALLATION 1) Install the body sie guard and install che sie 2) Tighten the bots to 5 Nem (45 fn. oe) (3) Insta he support tab bolts and gen to 11 Nan ght Ibs),23-34 HOOD. 1 HOOD ‘TABLE OF CONTENTS pee page ince ADJUSTMENTS REMOVAL st" ADJUSTMENT 3 ooo REMOVAL s REMOVAL 34 INSTALLATION ec INSTALLATION o HINGE HOOD REMOVAL REMOVAL (1) Remove the seger arms, (Refer to 8 ELEC. (I) Raise ond support the hed, ‘TRICALWIPERSWASHERSWIPER ARMS (2) Disconnect the underhuod lamp wire harness REMOVAL) enmecton (2) Rerowethe cowl pela sereen. (Reler to 23, BODYIEXTERIORICOWL GRILLE AND SCREEN REMOVAL) (G) Remove the bolts attaching the hinge ta the "a) Using @ wax pent, mark the positon of the Inge on the hood for installacian alignment refer 1G) Rewnve the serews attaching the hinge co the ood ig (6) Separate the hinge fram the heed INSTALLATION (0) Prepare and paint the replacement hinge to natch the body pain clr (2) Align the hinge with the dnsalaion reference marks on the hood (3) Incall he screws attaching the hinge to the hoa an eld tigen the a 24 No (8 fT). (@) Install the bolts stacking the inge to the '@) Install the covet panel and sercen, (Refer to 23 BODYIEXTERIORICOWL GRILLE AND SCREEN INSTALLATION} (6) Insiall the wiper arms. (Refer to 8 - ELECTR ‘CALAWIPERSINASHERSIWIPER ARMS - INSTAL. TATION) (3) Disconnect the windshield washer naz. (a) Disconnect the ground strap (5) Mark the poston ofthe hinges on the hood for {Gl Rewnve the screws aluahing the fa to che hinge ana rerpove the hood (Fi. (1) IF the hood must be replaced. remove and fod and safety loth to the replacement hae (Fig. 0 INSTALLATION (0) Poston the hood on the vehicle and install the screws atarhing the hte co the Hood. (2) Alp he funyes wth He saan eerence ‘mats of he hood and ghten the hinge sees to 28 Na (18 Ios) 16) Connect the uindorhod lamp wire hares a Ta! Come the windneld washer mazes (8) Connect the ground step. ADJUSTMENTS ADJUSTMENT “The hood Hinge screw hols are overt to fh {t) Lovsen'the screws (2) Move the hord tthe directions) requ for (3) Tighten the eresHOOD SAFETY LATCH REMOVAL (0) Raise and supp dhe hood (2) Remove he bolt attaching the safety taut 1 the howd tig. 2. (3) Remove the latch from the hood INSTALLATION (0) Peso he tate the Ho (2) knsta te bat ataching the safety tte tothe Toad anid tte to 9 Ne BD in bs) (3) Remove the support rod ar else the beod Fig. 2 HOOD SAFETY LATCH23-36 INSTRUMENT PANEL 1 INSTRUMENT PANEL ‘TABLE OF CONTENTS pee page ACCESSORY SWITCH BEZEL, INSTALLATION 6 REMOVAL 38 GLOVE BOX CHECK STRAP ‘AXLE LOCK SWITCH INSTALLATION a DESCRIPTION. ST GLOVE 80x LATCH STRIKER OPERATION Sr" REVOVAL 43 ‘SwiTCH ST GRAB HANDLE. REMOVAL ae RevOWaL 45 BASE TRIM ‘GRAB HANDLE BEZEL REMOVAL se “REMOVAL 46 INSTALLATION 39 INSTALLATION 46 (CENTER BEZEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 40 _ INSTALLATION 4 ‘CLUSTER BEZEL STEERING COLUMN OPENING COVER INSTALLATION 44 _ INSTALLATION 4 Love 80x To? cover REMOVAL 42 “REMOVAL 4° DISASSEMBLY 42° INSTALLATION 0 ACCESSORY SWITCH BEZEL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ‘COLUMN, OR INSTRUMENT PANEL COMPONENT UATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS Ig THE ONLY SURE WAY TO DISABLE THE ARBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL (1) Disconnect and isolate the battery negative cable, (2) Remoun the center bezel from the tstrument pone, (Refer to 23.” BODYIINSTRUMENT PANEL! ENTER BEZEL - REMOVAL) (3) Remove the four sews that secure the acces sory switch bezel co the instrument ponel (Fig. Fig, 1 ACCESSORY SWITCH BEZELw ACCESSORY SWITCH BEZEL (Continued) (4) Pull. ehe accessory sich bezel away fom the Instrument panel far enough to eccess the Ist 1G) Disconnect the metrmnent panel wire harness ‘ampectors fom the connector receptaces for the (G) Remove the accessory sich bezel from the instrument pane INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO: LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS I THE ONLY SURE WAY TO DISABLE THE AIRBAG CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG. DEPLOYMENT AND POSSIBLE PERSONAL inuuRy. (0) Pasion the accessory switch bea! to the inatoument panel (2) Reconnect the instrument panel wire harness ‘connectors a the connector eeeptatls forthe sees (3) Posidon the acessery switch bezel onto the Instrument pane. 1a) stall and tighten Une four sews that secure the acensory switch bezel tthe instrument pel “Tighten the serews 0-2 Nim (20 hs (9) Relmtall the center bezel ont the instrument ponel (Refer to 23” BODVINSTRUMENT PANEL! CENTER BEZEL - INSTALLATION), (@) Reconnect the batery negative cable AXLE LOCK SWITCH DESCRIPTION equipped, the Axle Lack switch fy acted nthe Accessory Switch Bezel, belo te HVAC controls ‘The switch will activate the Rear AMle locker and ReariFront Axle lrker The switch Isa double action Secured by snap it within the bezel. The axle Lock Switch cannot be repatred and, i faulty or damaged the entre switch must be replaced, INSTRUMENT PANEL 23 - 37 OPERATION fused B(o) crit fom fuse in che Power Distrbu tion Center (PDC), The switch Is grounded at all tne Tle Lack swish oly apron wn ‘With the transfer case Inthe AWD Law Range and the vehlele speed below 10 MPH (LOkp 3 omen ec st Push: Rear Ane Locked Momentary pushes, il tpale berween Rear Ae Lacked or RearFroat” Axle Locked. A womentary push to the upper porn of the racker sult FOFP* oth axes unlocked DIAGNOSIS AND TESTING - AXLE LOCK ‘SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR: ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO. DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- GAUTIONS COULD RESULT IN ACCIDENTAL AIR: BAG DEPLOYMENT AND POSSIBLE PERSONAL uurv. (0) Cheek the faned Bt) fase tthe Power Dist inition Cemer (PDC). OK. go to step 2 It mt repair the shorted eitcult or component required ard replace the fase. (2) Check for battery voltage a Ue ned Bs) ase inthe PDC. If OK. ga to sep 2 If not, repair the open Bis) cieat to the Tse 1G) Turn the lntion to the of poston, Disconnect ‘nd soate he negative batery cable Remove the ‘Anle Lace switch: Biscect the switch Heres cnr rector, Check far continuity between the fuse cavity Inte PDC and the Fused B() circuit in he swith ‘epithe oper Fused Bf) etre {al Turn the ignition to the of puna Disconnect and solate the negative battery cable Remove the ‘Ante Lack sich eaconnect the switch harness cn ‘round and a known good ground, If OK got o step Site OK: repair open ground cree23-38 INSTRUMENT PANEL AXLE LOCK SWITCH (Continued) (©) Turn the Ignition tothe OFF postion, Dison nectand Isolate the negative battery cable. Remove between each of the Enable circuits aed each af the {or and the cluster harness cannectors. IF OK to slop 6 I aoe OK. repair Use res as required {G) Turn the ignition tothe OFF postion. Dison rect and Isat the negative battery ele. Remove the anle Lark switch Dipconnect the site harness Request circuits, between the switch harness cane: torn cach ofthe Tacker relays inthe PDC. OK tent Cluster secon of the appropriate Body Menal fr the Chasse Diagnostic Mania ar perform the Sprit spr no: OR eae se REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AlR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, OR INSTRUMENT PANEL ‘COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY. NEGATIVE (GROUNO| CABLE, THEN WAIT TWO MINUTES FOR ‘THe SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE ‘THis 18 THE ONLY SURE WAY TO DISABLE THE [SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT [AND POSSIBLE PERSONAL INJURY, {Bisons an late she ary ove (2) Remove the accessory switch bezel trom the Instrument panel center bezel from the instrument Panel Refer to 23 ~ BODY INSTRUMENT PANEL! ACCESSORY SWITCH BEZEL. REMOVAL) (G) Using a trim stick or amather suitable wide Matbladed ool gently pry the latch tbs at che Lop ‘ecessory sisitch bezel far enough ta disengage the Shap Teecures onthe switch housing then pull the Sulth out of the receptacle (ig. 2), 1 a ate She nei= ‘ AE IL Fig, 2 ACCESSORY SWITCH REWOVE INSTALLATION 'BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT ‘SYSTEM BEFORE” ATTEMPTING. ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON NECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR ‘THE SYSTEM CAPACITOR To DISCHARGE BEFORE PERFORNING FURTHER DIAGNOSIS OR SERVICE, ‘THis 1S THE ONLY SURE WAY TO DISABLE. THE TAKE THE PROPER PRECAUTIONS COULD RESULT IN. ACCIDENTAL AIRBAG DEPLOYMENT 0) Postion the axle lock switch over the proper (rig. (2) Evenly push the axle lack sirtch into the recepacie nt the sap features onthe top ar tom of the switch housing are Tall engaged Ts the receptacle Instrument panel (Refer to 25 BODYINSTRU. MENT PANEL/ACCESSORY SWITCH BEZEL. INSTALLATION). (a) Reconnect the batery negative cablew BASE TRIM REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS Ig THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIGLE PERSONAL 1) Disconnect ond isolate the battery negative (2) Remove the istrument cluster from Use esr rent panel (Refer Io. 8 FLECTRICALINSTRU MENT CLUSTER - REMOVAL). (G) Remove the accessory swith bezel from the Instrument panel (Refer to 23. BODYINSTRU MENT "PANELIACCESSORY SWITCH BEZEL REMOVAL) (4) Remove the grab handle bezel from the str rent panel (Refer to. 23. BODYNSTRUMENT PANELIGRAB HANDLE BEZEL” REMOVAL), (©) Remove the speakers fran ube instrament panel. (Reler to #- PEECTRICAUAUDIOSPEAKER REMOVAL, 1G) Remove the radio fam the instrument panel (Relor ta B= ELECTRICALAUDIOMADIO. REMOVAL), (7) Rene the heatersAC sonia feo he esr tment pone (Refer to 24 HEATING & AIR CONDI TIONINGICONTROLSIAC-HEATER CONTROL. REMOVAL) (8) Rene the outboard heater: MC panel outlet harrels row dhe istrument panel Refer to 24 HEATING f AIR CONDITIONINGDISTRIBUTION’ PANEL OUTLET BARRELS RENOVAL). (0) Reno the inirament panel from the vice (Rel to. 23 BODYINSTRUMENT PANEL REMOVAL) (U0) Plice the instrument ant on 2 sueable work protect the instrument panel Ir any penile cow rete damage (11) Remove the passenger alrbax door fram the lestrument ped eler to 8 ~ ELECTRICALRE: STRAINTSPASSENGER AIRBAG DOOR = REMOV A) INSTRUMENT PANEL 23 - 39 12) Remave the wo screws that secure the sway dato link connector to the instrument pane ter ofthe instrument pane! that secure the base trim {othe stractural suppor. 4) Remave the base rim fom the instrument INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH _AIR- ATTENPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER. Is THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR” uur’. (0) Pasion the base trim onto the instrument panel stricture spot (2) Install and ight all of ve srews around the perimeter of the olsument panel that secure the few trim to the strucral ‘sport Tighten the Serews t02.Non @D in Ibs) (3) stall and titers the two sre that secure panel, Tighten the srews to 2 Nav (20. Ibs) (G) Retna the pasenger alba door Into the Instrument pans (Relor to 8.» ELECTRICAURE STRAINTSPASSENGER AIRBAG DOOR INSTAL: TATION, 13) Reinstall the instrument panel sto te vice (Refer to 23. BODVANSTRUMENT PANEL INSTALLATION). 16) Reinstall che outhoord heater AIC panel autlet boars into the insiumene panel. Refer to 24 PANEL OUTLET BARRELS - INSTALLATION). (7) Reinstall the eter AC cote ino the st sent panel Refer 920 HEATING © ALB CONDI (ONINGICONTROLSIVC HEATER “CONTROL. INSTALLATION). 18) Reinstall th radio Into she instrument panel (Refer to. 8 ELECTRICALAUDIORADIO. INSTALLATION. 10) Reisstall the speakers eto che instrument panel. (Refer to 8 - ELECTRICAL/AUDIOSPEAKER, 100) Reinstall the grab handle bezel orto the Instrument pana (Reler wo 23 - BODYMINSTRU23-40 INSTRUMENT PANEL BASE TRIM (Continued) MENT PANELIGRAB HANDLE BEZEL - INSTAL. LATION, instrument panel ter to 22 = HODVANGTR MENT PANELIACCESSORY SWITCH BEZEL INSTALLATION. (12) Reinstall the instrument caster into the frstrument panel (Refer ta 8 ~ ELECTRICAL/IN STRUMENT CLUSTER - INSTALLATION) (13) Reconncet the battery negative eable CENTER BEZEL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS I THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG. DEPLOYMENT AND POSSIBLE PERSONAL (1) Disconnect and isolate the battery negative (2) Remove the tap cover fom the instrument panel (Refer o 23 ~ BODYIINSTRUMENT PANE TOP COVER REMOVAL}. Fig. 3 CENTER BEZEL 1 (9) Remove the two screws that secure the top of the center bezel to the tap af the fstrument panel Mirae sappert. (Fe. 3 {H) Using trim stice or anather suitable wide Net-laded oo. gently pry the ler edge of the en (3) Pall the lower edge af Use center bez away from the istrument pane! far enough to diergge the four snap clip retainers that secure it 10 the receptacles In the instrament pane base tin TG) Remove the center bezel from the fstrument pone INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH_AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS [Is THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- GAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT ANO POSSIBLE PERSONAL nuuey. 0) Poston the center bezel ete the instrument (2) Align the snap clips on the center bezel with the receptacles in the Instrument panel base tim 13) Using hand pressure, press firmly on thee ter bezel rer each ofthe snap lip lcaons unt acs of dhe sup lips is fll engaged es recep ‘le in the instrument panel base te {a} ntl and tighten the two rows that secure the top af the enter bee! to the top of the iste ‘ment pane structural suport. Tighten the sews to 2 Nim 20 nts). (61 Reinstall the wp cover onto che tnscrument {TOP COVER - INSTALLATION, (6) Recuaneet the battery negative cablew CLUSTER BEZEL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS Ig THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIGLE PERSONAL 1) Disconnect ond isolate the battery negative (2) Remus the steering enumn opening over fram dhe iastruipent panel [ler to 23 BODYIN STRUMENT PANELISTEERING COLUMN OPEN. ING COVER - REMOVAL) 13) Remove the tap cover fram the instrument INSTRUMENT PANEL panel Refer «0.23 © BOD) TOP COVER “ REMOVAL}, (4) Remove the two acres that secure the lower panel (Fi). Fig. 4 CLUSTER BEZEL LOWER SCREWS REMOVE! INSTALL (©) Remove the three screws chat secure the upper instrument panel (Fig. 5) 1G) Renove the chster bezel from the instrument pe INSTRUMENT PANEL 23 - 41 Fig. 5 CLUSTER BEZEL UPPER SCREWS REMOVE! INSTALL INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH_AIR- BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND 150- TATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG S¥S- ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS Is THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIGLE PERSONAL (0) Pasion the luster bezel ante the instrument pene 1 tal an gn th hve crn ht sce top of the istrament pone (Fig. 5). Tighten the ‘ews to Nom (2 nt). (3) stall and tighter the two srews that secure Inserwment panel (Fig. #). Tian the screws to 2 Na 20 i, To (3) Reinstall the top cover onta the inssrument pane. tele to 25." BOBYANSTRUMENT PANEL ‘TOP COVER - INSTALLATION, (6) ReMnstall the steering elummn opening cover nto the Insiument panel Reler ta 24 BODYIN STRUMENT PANELSTEERING COLUMN OPEN ING COVER - INSTALLATION. 16) Recarneet the battery nogative cable23-42 INSTRUMENT PANEL GLOVE BOX REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR. BAGS, DISABLE THE AIRGAG SYSTEM BEFORE [ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: Ig THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIGLE PERSONAL 1) Disconnect ond isolate the battery negative 12) Release the glovebox latch and open the glove tn dose 3) White supporting the glove bax door with one hand rasp the check strap as lose tthe glove bo ‘ear as posable a slide the rolled end ofthe check Strap out af the slot inthe edge ofthe dor (Fig @ Fig, 6 GLOVE BOX REMOVE/INSTALL (@) Lower the glovebox door far enough to den age the hinge hook Formats on the lamer edge of 1 the door from the hinge pins on te lower edge ofthe Instrument pane DISASSEMBLY Some of the component of the glove box used in this vehicle are serviced Individually. The serviced ‘cmponents Include the glove fox latch and handle tink and the love box lock evlinder (Fi. 7) Follow ponents fom the glove bax WARNING: ON VEHICLES EQUIPPED WITH _AIR- ATTENPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- ‘TEM CAPACITOR TO. DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS ‘SYSTEM. FAILURE TO. TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- JAG DEPLOYMENT ANO POSSIBLE PERSONAL | Fig. 7 GLOVE BOX COMPONENTS (0) Disconnect and isolate the battery negative (2) Remave the glove box om the instrument ponel Refer to 23." BODYIINSTRUMENT PANELw GLOVE BOX (Continued) () Remove the four screws that scure the glove bax latch and handle tothe glove bax door fon the Va) Rersove the Latch and handle fom the inside of the glove box done (LOWE Box Lock crumoER (0) Remove the glove box lateh and handle uni AND HANDLE (2) Insert the key into che glove box lack yl: (5) Inert a small server tnt tne retain Mer Fg Fig. 8 GLOVE BOX LOCK CYLINDER REMOVE/ INSTALL (@) Usiog enti vsti end pling eta with te ke. pu the lock einer ct of the glove box Tate and hone ni ASSEMBLY Some of Uhe camponens of the glove box used in Uni aad the glove box lok einer (Fly 7). Fallow Ing are the procdires for assembling these compo rents onto the glove bon WARNING: ON VEHICLES EQUIPPED WITH _AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE [ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS INSTRUMENT PANEL 23 - 43 1S THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- BAG. DEPLOYMENT AND POSSIBLE PERSONAL inure. ‘GLOVE Bor LATE AND HANDLE (0) Poston the latch and handle one the nse of (2) Install and ten dhe four ses that secure the glovebox Iatch and handle tothe glove box door Front the Inside of the glove ban. Tighten the sews 12 Nim (20 in tbs). (5) Reistall the glove box onto the instrument panel, Refer t0.23 » BODYINSTRUMENT PANEL! [GLOVE BOX "INSTALLATION. (a) Reconnect the battery nepative cable ‘GLOVE Box Lock crLMOER (4) ner the Key sn the give ba ork yer (2) Using a gente twisting and pushing action on the hey pis the lock eylinder ima the glove: Box (3) Reinstall the glove box latch and handle ents te lave box. Refer te GLOVE BOX LATCH AND HANDLE INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ATTENPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, "THEN WATT TWO MINUTES FOR THE AIRBAG S¥S- ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS Is THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR |AG DEPLOYMENT AND POSSIGLE PERSONAL uurY. (1) Pasion Ube pve bos to the instrument panel [2] Engage the hinge hook formations on the ler ‘eg ofthe love bx enor withthe hinge pts on he lower edge of the inirument panel (3) Tit the upper edge of the pve be dear toward the instrament panel far enough to engage the check strap with the door (Fi 8). Is) While supporting the pve tx door with one hand, grasp the check strap a8 close othe glove box oar posible and side the ralled end of the check Stop info the shat inthe age ofthe door {3) Close and latch the glove box doe (6) Recanect the batesy neat ele23-44 INSTRUMENT PANEL GLOVE BOX CHECK STRAP REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR. BAGS, DISABLE THE AIRGAG SYSTEM BEFORE [ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: Ig THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIGLE PERSONAL (0) ise (2) Renews the qlee toe fem the instrument nel (Refer 9 23" BODVINSTRUMENT PANEL GLOVE ROX “ REMOVAL) () Remove the screw that secures the glove box ect and tslate the battery negative check strap t0 the strament panel of the upper ‘love tic opening reinforcement ig sree == —| Fig. 9 GLOVE BOX CHECK STRAP (4) Remove the heck strap fram Ube upper love bx oping reinforcement INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE 1 ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT UATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRGAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS I THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR. inure. U)Poston the check strap te the upper sve box opening reintincernen (Fi. 9 (2) tnstall and tighten the Seve that secures the love bax check strep tothe upper glove box opening Feiniorcenent Tighten the serew to 2 Ne (20 in Toe). (3) Relnstall the wave box onto the inscrument ponel (eter to.25 " BODYINSTRUMENT PANE GLOVE BOX INSTALLATION. (4) Recuneet the batery negative cable GLOVE BOX LATCH STRIKER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ATTENPTING ANY STEERING WHEEL, STEERING ‘COLUM, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT ANO 150. LATE THE BATTERY NEGATIVE (GROUND) CABLE, FORMING FURTHER DIAGNOSIS OR SERVICE, THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIDLE” PERSONAL nuurv. (0) Disconnect and isolate the batery negative (2) Remove the glove box fem the instrument pane. (Refer t9 23 BODYANSTRUMENT PANEL GLOVE BOX " REMOVAL, (3) Remove the two sevens that secure the latch sariker tothe upper glove bax opening reiforcement (Fig. 10)w GLOVE BOX LATCH STRIKER (Continued) Fig, 10 GLOVE BOX LATCH STRIKER REMOVE! INSTALL INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE GATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAmT TWO MINUTES FOR THE AIRBAG SYS" ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE, THIS I THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG. DEPLOYMENT AND POSSIBLE PERSONAL inuuRy. (0) Peston the Inch striker onto the upper glove tax opening reinforcer Fi, 10) (2) install and tighten the 0 screws that secure the lich striker to the upper glove box opening ten forcement Tighten the setews to 2 Nem @0 In ths), 13) Reinstall the glove box onto the instrament panel. (Refer to 23 * BODYINSTRUMENT PANE (a) Resarect the batery negative cable. GRAB HANDLE REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR. ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE GATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG 23-45 INSTRUMENT PANEL, SYSTEM, FAILURE TO TAKE THE PROPER PRE- ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- inure. (1) Disconnect and isclate the battery negative 12) Remove the glove box fram the instrument ponel,(Reler to 23" BODVINSTRUMENT PANEL! GLOVE BOX “REMOVAL, (3) Reach through and above the glove box opens ‘ent panel structural support (Fi, 11}. Diseard the Fig, 11 GRAB HANDLE REMOVEINSTALL INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH _AIR- ATTENPTING ANY STEERING WHEEL, STEERING LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER. FORMING FURTHER CIAGNOSIS OR SERVICE, THIS Is THE ONLY SURE WAY TO DISABLE THE AIRBAG. ‘SYSTEM. FAILURE TO. TAKE THE PROPER PRE ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR- nuuev. (0) Posidon the grab handle enw the fae of the Instrument pane NOTE: Atways use now fasteners to Install he grab handle, The removed grab handle fasteners should be discarded23-46 INSTRUMENT PANEL GRAB HANDLE (Continued) stud on each end of the grab handle to the Inst tment panel structural support (Fi UI). Tighten the tts eo 8 Ni (30 In Ibs) (3) Reinstall the glove bot iota the instrument panel (Refer to 23 BODYIINSTRUMENT PANEL (a) Resarect the batery negative cable GRAB HANDLE BEZEL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: ‘COLUMN, (OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WATT TWO MINUTES FOR THE AIRBAG SYS- ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS 15 THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘CAUTIONS COULD RESULT IN ACCIDENTAL ‘AIR. BAG DEPLOYMENT AND POSSIBLE PERSONAL (1) Disconnect and isolate the batery negative abe, (2) Remove the gra handle from the instrument pone. (Refer to 23.” BODYIINSTRUMENT PANEL! GRAB HANDLE - REMOVAL) (3) Remove the glove box latch striker from the Instrument. panel. “Refer to 23 - BODYAINSTRU. REMOVAL), (4) Remove the ewo screws that secure the grab ht ret te per we espe Fig, 12 GRAB HANDLE BEZEL REMOVEINSTALL (©) Remove the grab handle ezl from the ist 1 INSTALLATION BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTENPTING ANY STEERING WHEEL, STEERING DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO. DISCHARGE BEFORE’ PER. FORMING FURTHER CIAGNOSIS OR SERVICE. THIS Is THE ONLY SURE WAY TO DISABLE THE AIRBAG. ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- nur’. ment panel (Pig 19) the grab handle bezel to the upper glovebox open Feinfrcement, Tighten the screws fo.2 Nav @2 in Tis). {3} Reinstall the glove box latch striker onto the love box opening upper reinforcement (Refer to 23 BODY/INSTRUMENT PANELIGLOVE BOX TATCH STRIKER» INSTALLATION). (4) Reinstall dhe grab handle ont the instrument panel (Refer to 28." BODYANSTRUMENT PANEL! GRAB HANDLE - INSTALLATION. INSTRUMENT PANEL, ASSEMBLY REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- ATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS [8 THE ONLY SURE WAY TO DISABLE THE AIRBAG BAG DEPLOYMENT ANO POSSIDLE PERSONAL nuury. NOTE: Setore starting thie procedure, be certain to {ur the steering wheel unt! the font wheels re It the straghtanead positionw INSTRUMENT PANEL ASSEMBLY (Continued) i) Disconnect sid Isolate the battery negative cable (2) Remowe the steering cum opening cover fram the fstrument panel Refer to 23 BODYIN. ‘STRUMENT PANELISTEERING COLUMN OPEN: ING COVER - REMOVAL), (@) Remove the stering column fram the vehicle, but do mit remove the ever aithag, the elering ‘wheel the switches fram the steering colar. Be ‘certain thatthe stering wheel is osked and scared tering (Reler to) 19 - STEERINGICOLUMN REMOVAL) (A) From beneath the drier: of he str rent pal, perfrm the following (a) Disconnect the instrument panel wie har ress conmectors from the 100-vay cross ba ire 1D) Disconnect the driver side winow denser hose ot the heater NC housing demisterdeeoster uct, (3) Remus the ployee frm the instrument ponel Refer to 23 " BODYINSTRUMENT PANEL! GLOVE BOX” REMOVAL), (0) Reach through the instrament pane gave bor pening to perorm the elowing {ah Disconnece the hester’C conv vacwun hamese connector from the hester XC hosing ‘acim harness camnetor 12) Disconnect ihe inatrument pane wire ter seas connector frm the healer AC housing wire hamese connector, (6) Disco the cron Body wire harness ca Ua Disconnect the passenger se window dermis: ter hose at the heaterAUC housing, demstertde Te) Disconnect the wo halves of the radio ‘antenna canal cable connector. I Remove te ats that sec the pases set airbag lawer bracket to the studs othe da Panel Fig 13) {i)"Remoee the top. cover fam the. tnatrument panel (Refer © 23 - BODYIINSTRUMENT PANEL! ‘TOP COVER “REMOVAL (&) Remove the thee screws thot secure each end of the instrument panel structural supporto the ‘al side ter panels atthe fort ofeach dor oe tng (Fig 1). 9) Retnave the four nuts that secure the top ofthe Instrument panel stractiral support tthe stds on the top of the dash panel. INSTRUMENT PANEL 23 - 47 Fig. 13 PASSENGER AIRBAG LOWER BRACKET ‘NUTS REMOVEINSTALL Fig, 4 INSTRUMENT PANEL REMOVE/NSTALL UO) With the aid of am asitant Hehe Hosta rect pel off of the es panel tt and remove from che vehicle23-48 INSTRUMENT PANEL 1 INSTRUMENT PANEL ASSEMBLY (Continued) INSTALLATION BAGS, DISABLE THE AIRBAG SYSTEM BEFORE [ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO DISCHARGE BEFORE PER. Ig THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM, FAILURE TO TAKE THE PROPER PRE- BAG DEPLOYMENT AND POSSIBLE PERSONAL INURY.. (1) Wen the ald of an assistant, poston the Instrument panel into the vehile and onto the dash Panel stds Fi. 14) (2) Install ana Ughten the four nuts that secure the top ofthe instrament pana structural suppert to fats 12 Ne (105 fb) (G) Tastall and tighten the tee screws thet secure ‘ach end of the instrument panel stor spore ‘pening. Tighten the serews to 12 Nim (105. fs). a) Reina the tp cover onto the instrument panel (Refer to 23 - BODYIINSTRUMENT PANEL ‘TOP COVER “ INSTALLATION), (@) Reach through the instrument pane! glve box ‘pening to perform the ellewing (al Install and tighten the tu nuts that secure tne lower pasenger rb, bravket tothe studs a the dank pene (Figs 13) Tighten the mats to 28 Naw (i te Ios) (t) Reconnect” the two halves of the radio antenna ean cable conmector [o) Reconnect the passenger ste window dems tor hose to the heater AC housing demisteride Troster dt (a) Recarnet the rans ody wee hares co rector ta the passenger air pital wie canner 'e) Reconnect the instrument panel ere harness connector tothe heater NC hawsing wire harness 1) Reconnect the heater ACC control vacuum hamess connector tothe heater AC housing voc (Gy Reinstall the sve bot goto the instrument panel (Refer wo 23 * BODYINSTRUMENT PANEL. GLOVE BOX “ INSTALLATION). (7) From beneath the driver deaf the instrument (a) Reconnect the driver side window denistr hose tthe heater NC housing deiisterideroser 10) Recumect the instrument pare wire harness carectors to the {00-wey cross bndy wire harness ‘nneetor near the lft oe side er pane, [s) Reinwal the steering salon into the vehicle Be certain that the steering wheel is lucked apd ‘secured frm rotation to prevent the Toss of lock Spring centering. Refer to 19 - STEERINGICOL, UMN INSTALLATION) (0) Reinstall the steering ctumn gpening cover ‘nto the insteument panel. (Reler to 23 BODYAN. STRUMENT PANFUISTEERING COLUMN OPEN. ING COVER - INSTALLATION, UO) Reconnect the baitery netive cable STEERING COLUMN OPENING COVER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUM, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘TEM CAPACITOR TO DISCHARGE BEFORE PER: FORMING FURTHER DIAGNOSIS OR SERVICE. THIS SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT ANDO POSSISLE PERSONAL (0) Diacnnct aad isolate cae attry agate cable {2 IF the vehicle 1s so equipped. move the 4 stcering clu tothe fly Tas peste {3 Remove he two stews that eur he seeing {tral support tg 1) Ta) Using 2 tn ale or enather suitable wide tun open cover away fan te instrument panel teach ie of the seeing coluin fr nought di spe th sp rer ot ar 13) I he yh so equpped ll te wp of the ss a ap ce er ar oh {ete ead leveling sic ho the sch can rector eeepcw INSTRUMENT PANEL 23 - 49 STEERING COLUMN OPENING COVER (Continued) ‘lg, 15 STEERING COLUMN OPENING COVER "REMOVE/NSTALL (©) Pull the top of the steering column opening caver rearvard fae enough Wo aisenape the hinge hak formatter on the lower edge ofthe caver from sheng pon the Toner go ee rane (7 Remove the steering column opening over from the instrument pane INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR: BAGS, DISABLE THE AIRGAG SYSTEM BEFORE [ATTEMPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO: LATE THE GATTERY NEGATIVE (GROUND) CABLE, TEN CAPACHIOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE, THIS I THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘CAUTIONS COULD RESULT IN ACCIDENTAL AIR: BAG. DEPLOYMENT AND POSSIBLE PERSONAL (1) Poston the steering column opening cover to the Instrument panel edge ofthe searing Catucn opening cover with Une Ting pins on the lawer edge of the istrament peel mr 13) (3) If the vehicle xo equipped, ol the top ofthe tering eae opening eaver upward [ar ena to Teconpec the wire harness connector for the head Tamp leveling switch to the seth connector recep (8) Tit the upper age ot the steering column ‘pening cover up and align the two snap lip eta freon ae nh eae ne 15} Using hand pressue, press Rrnly on the steer tng column opening eover over each of the shep ep tan nh each oe sap sip ty rg (6) Insta and Tighten the two sees that secure te scering calum opening ever to the instrument panel structural support Tighten the screws w 2 New (20 in Ibs (7) Reconnect the batery negative cable TOP COVER REMOVAL WARNING: ON VEHICLES EQUIPPED WITH _AIR- ATTENPTING ANY STEERING WHEEL, STEERING ‘COLUMN, OR INSTRUMENT PANEL COMPONENT LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WATT TWO MINUTES FOR THE AIRBAG SYS- ‘TEM CAPACITOR TO. DISCHARGE BEFORE PER: Is THE ONLY SURE WAY TO DISABLE THE AIRBAG ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT ANO POSSISLE PERSONAL uur’. 1} Disconnect and iselate the battery. negative cable,23-50 INSTRUMENT PANEL ‘TOP COVER (Continued) (2) Using @ erm suck or anather suitable wide fat bladed too, gency pry the Instrument poi top coough to dsengage the five aap clip retainers tome theie receptacles tn the intrument panel structural Sinner (Pi 10) Fig. 16 TOP COVER REMOVENNSTALL (5) Remove the top cover fam the instrument 1 INSTALLATION BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTENPTING ANY STEERING WHEEL, STEERING DIAGNOSIS OR SERVICE. DISCONNECT AND 1S0- LATE THE BATTERY NEGATIVE (GROUND) CABLE, ‘THEN WAIT TWO MINUTES FOR THE AIRBAG SYS: ‘TEM CAPACITOR TO. DISCHARGE BEFORE PER: FORMING FURTHER CIAGNOSIS OR SERVICE. THIS Is THE ONLY SURE WAY TO DISABLE THE AIRBAG. ‘SYSTEM. FAILURE TO TAKE THE PROPER PRE- BAG DEPLOYMENT AND POSSIELE PERSONAL nuurY. 0) Pasion the top caver onto the instrument net (Fig 10, (2) Alin the snop clips on dhe top caver with the snap clip receptacles in the instrument panel sic {ural suppor. 13) Using Tint pressure, press fry downward con the top caver over each af the stp dip loations {uni each of the sop clips 5 fll Seated in its Tecnptace an the instrament panel sractaal sp (A) Recarnect the baltery negative ebw INTERIOR 23-51, INTERIOR TABLE OF CONTENTS pee page [AOD-ATRUNK INSTALLATION 5s REMOVAL 5) CENTER CONSOLE FRONT CARPET INSTALLATION 6 REMOVAL 52 CENTER CONSOLE CUP HOLDER INSTALLATION 52 REMOVAL 6 ‘CENTER CARPET INSTALLATION & REMOVAL 52 CONSOLE LOCK CYLINDER INSTALLATION 52 Revoval, 6 REMOVAL 2 SPORT BAR INSTALLATION 5 REMOVAL 7 WHEELHOUSE CARPET INSTALLATION 7 REMOVAL 52 AILLAR TRIN REAR VIEW MIRROR INSTALLATION se REMOVAL 53. REAR HEADER TRIM INSTALLATION 5 “Reyoval @ REAR VIEW MIRROR SUPPORT BRACKET INSTALLATION 2 INSTALLATION ‘54 WINDSHIELD HEADER SunvisoR REMOVAL 9 REMOVAL 54 INSTALLATION # SHIFT BEZEL - AUTOMATIC TRANSMISSION REMOVAL @ REMOVAL 54 INSTALLATION 0 suier 80oT REMOVAL ss ADD-A-TRUNK REMOVAL U) Release laches under trun panel ard Me 12) Rennwe bolts attaching trunk «0 toner body panel (Fi (3) Seprate trunk fom vee INSTALLATION (0) Peston the trun iv the congo space (2) stall se bol Fig, 1ADD-A-TRUNK23-52 INTERIOR FRONT CARPET REMOVAL (i) IF necessary, remove the center console, (Refer 122.» BODVINTERIORUENTER “CONSOLE REMOVAL) (@) Rene the retainers attaching the carpet to ve cash panel (Fg 2 (3) Disengape the snaps under fret seats, (4) Remove carpet fem the vehicle Fg. 2 FRONT CARPET INSTALLATION (1) Poston the carpet the vehicle (2) Engage the snaps around under front seats. (3) nscale recainers ncaching te carpet tothe sesh panel (a) previasly removed, install the center com sole (Refer o 23. BODYINTERIORICENTER CON. SOLE» INSTALLATION) CENTER CARPET REMOVAL (0) Disengage the snaps under front seats. (2) Rermnve the carpet INSTALLATION (0) Poston the carpe nthe vehicle (2) Engage the snaps under fant seats 1 CARGO AREA CARPET REMOVAL 0) Poston the rear seat in the fld and cumbled (2) Pal dhe carpet from under the rear seat. (3) Remove the Add Trunk, equipped. Refer to 25. BODYINTERIORADD:A-TRUNK » REMOVAL) (a) Route the rear seatbelt buckles crag the 13) Separate the carpet frm the vehicle Fi, INSTALLATION (1) Poston the carpet in the vehicle (2) Route the rear seat ele buckles through the (3) lnstall the Ad@A-Trunk, equipped. Refer to 23; BODY/INTERIORADD-A.TRUNK = INSTALLA. TION) (a) Return the eear seat tothe full rearward posi WHEELHOUSE CARPET REMOVAL 1) Position the rear seat in the fll forward post (2) Remave the Add-A trunk, if equipped. (Refer to 23 BODVTINTERIOR/ADD-A.TRUNK » REMOVAL) (9) Grasp wheelhouse carpet and remove trom swehlae Fi. 3. INSTALLATION (0) Posidon wheelhouse carpet in vehicle ane (2) Install the AddAcrunk, if equipped. Refer to TION) 13) Return the rear seat ta the full earward pos3. interior 23-53 WHEELHOUSE CARPET (Continued) Fig, 3 VEHICLE CARPET REAR VIEW MIRROR REMOVAL 0) Loosen the mirror set screw (2) Ste the tro el he Support bation (oracke) (Fig INSTALLATION (0) Sie the mvieror anio the support. bution (oracke CAUTION: Do net ovortighton tho setscrow because lass chipping. andlor breakage could result 2) Tighten the mieor sescrew to 1 Nom (0 in wos) Fig, 4 REAR VIEW MIRROR23-54 INTERIOR REAR VIEW MIRROR SUPPORT BRACKET INSTALLATION (0) Mark te poston for ube mieor Bracket othe ‘utnie of Use wins plans wth aw pene (2) Clean the bracket contac area an the sss (Use ‘a snd powdered clesser ta cloth saturated ‘with Isoprpt (rubbing) alcohol Finally. clean the bla ith m paper towel dempened with alcoho {@) Send whe mrface on the supprt beackee with fine grtsandpoper. Wipe the brecket surface dean ‘with's paper toned (i) Apply accelerator to dhe surface nthe bracket sccocng to the following istewctene: ‘Crush the vial ta saturate the Felt applicator 1 Remove the paper slew, AAD mtn oh sn mac om he Allow the accelerator to dey fr ive nines = Dovnot touch the brocket contact surlace after (9) Apply adhesive sceerator 0 the bracket om tact sure onthe windshield glass. Allow the ace ‘erator t dry Tor ane manite, Do not touch the glass 16) Install the bracket according to the folowing Instructions ‘Apply an even coat of adhesive to the contact surface on the Bracket w'Nlign the bracket with the marked position en te indole "Pros an fld te brocket in place for at lease ‘one mint, NOTE: Verity thatthe miror support bracket is cor- recty aligned, because the adhesive wil cure rap ray, (Allow the adhesive to ae for 10 mlrtes ‘eed lth (8) Allow the adhesive to cure for an adational £10 minutes before installing the miro 1 SUNVISOR REMOVAL 1) Remove the serous thot atch the sunssar arm suport backets co the winshild trae Fy 5) (2) Remove the ‘snvisor trom the windshield frame. Fig. 5 SUNVISOR INSTALLATION 1} Poskon the sunssor on the windsheld frame 2) install the serews that atach the sunwisae arn support brackets tothe frame. Tighten the sre SHIFT BEZEL - AUTOMATIC TRANSMISSION REMOVAL (1) Pal sit ever hana ff sift ever ig (2) Using a. trim. ack C7435. or equivalent remove the shift ez (3) Twist snd remove che bezet ih INSTALLATION 1) Cana he a bert Hy wing te (2) Pasion the sift Deel aver the shift lever and snatall onto the console 13) Align the shifter handle keyways and push3 INTERIOR 23-55 SHIFT BEZEL - AUTOMATIC TRANSMISSION (Continued) lg, 6 SHIFT BEZEL SCRSEREEZ Ee cours) SHIFT BOOT REMOVAL (0) Using trim stick C-ATSS or equivalent. pry the shit bce fom the bere! (2) Using na lds py he perm (G) Remove the nut attaching the sit Keb tothe shift ever (Fg (4) Remove the knob and sie the shit box from Fig. 7 SHIFT BOOT INSTALLATION (0) Slide the shit tout over tbe shit lve (2 Snap the shit boot sta pace the center an se, rt and tighten to34New (8 fe tbsys {ah Poston the SN patter user an he Kod sand pres nto place. CENTER CONSOLE REMOVAL (0) Remave the cup bales f equipped. (Refer to 2a BODYANTERIORICENTER CONSOLE. CLP. HOLDER ASSEMBLY - REMOVAL) 12) On fl console models remove the erm de from the bottom af the cup baler (Fig. 10), 13) Remave the autanatie tranansion shit bezel Ir equipped, (Refer to 23 » BODYINTERIOR/SHIFT 1G) Using a tei tick C7455 or equiv remove the oir bag deactivation switdh ai dice tect the electrical connector, eqalpped 16) Remove the bls) attaching the console to the oor pa ig 8) weg (6) Shit transfer ease to four tow pasion, (7) Shit transmission to 1 nd gear Tor wal Fig. 8 MINI CONSOLE23-56 INTERIOR CENTER CONSOLE (Continued) Fig, $ FULL CONSOLE INSTALLATION (0) Connect the electrical connector and ina console wer assembly aver the park beake lever, ‘quipped (2) sill the wer bots, (G) tntall the mink ecracke assembly over the Inansmissin and transfer eae aifers, (4) Incall the console bat (5) Connect the a bag deactivation switch elect cal consector and instal the sith, I equipped. ‘al connectr ad install the swith, If equpped (7) incall the auto transmission shift eae AC BEZEL INSTALLATION) (@) ntl che manual transmsson shift bot. if ‘equipped. (Refer 40.24 ~ BODYINTERIORSHIET BOOT INSTALLATION) (©) Install the cup holder and wim disc af ‘equpped. (Refer t0:23 - BODYINTERIORCENTER CONSOLE CUPHOLDER ASSEMBLY TION) INSTALLA, 1 CENTER CONSOLE CUP HOLDER REMOVAL 1) Using a trim stk C4735. or equivalent remove the cp holder tert (Fig. 10) ae (Pig §) (2) On mint console equipped mods remove the tlt end remive the cup halen Fi. 8) Fig, 10 FULL CONSOLE CUP HOLDER INSTALLATION (1) On mini console equipped mades instal the up holder and instal the bate {2} Tighten the bole to No (3) install the cup bolder ier. CONSOLE LOCK CYLINDER REMOVAL 14) Open the conse cover (2) Remove the screw that ataches the retaner to (Fig. tn, (3) Remave the lock eytinder ftom the consolew CONSOLE LOCK CYLINDER (Continued) Fig, 11 CONSOLE LOCK CYLINDER INSTALLATION (0) Ensert the soured lace the cole aver SPORT BAR REMOVAL 0) Reread cap andor sot top. (Refer wo 23, REMOVAL) or (Refer to 23 - BODYIREMOVEABLE. TOPSOFT TOP = REMOVAL). (2) Removes the dor opening fares. (Reler to 23 BODYINTERIORDOOK OPENING | FRAME REMOVAL) (3) Remove the sunvisars. (Refer to 23 - BODYIIN. TERIORSUN VISOR - REMOVAL) (4) Rem che apie weathersnps (5) Remove the speaker pes. (Refer ta 23 - BODY! INTERIORSPORT BAR" SPEAKER POD. REMOVAL) (6) Disensage coer support bar caver zipper (7) Rermove the bolts attaching the sport bars (0 the center support bar (12) a) Rene the belts attaching the side support 10) Rerove the bolts attaching the side suppore bars co the sport bars (UO) Separate the se support bars fon the vei (U1) Pull back dhe center section ofthe carpet and remo the bolts attaching the spare bart the args Moor pane (U2) Renave the bol tual the sport bar to the brackets behind the door strikers, INTERIOR 23-57 (U3) Lower the rear seat and lt rear seat tothe Full oeward postion UA) Pal ek wheethouse cape and remave Bolts ‘attaching the sport bars to Use wheelbase U5) Remove the bolts attaching the seatbele U5) Carefalty tthe sport bar upward and rentove i ro the wohl U2) necessary, remove the pads and coves from the sport bar INSTALLATION (0) It cessary, transfer all attached componens ih ion th Saute nat wre rere oo {3} Apply epaay chromate primer to the attaching hole edges for protection agalnstcorosan (a) Pskon the p ort pten bn he Roe NOTE: To prevent water seepage, apply 3M Orip- Chek Sealant for an equivalent product) to the Underside of te sport bar base flanges and all the bolt heads before instalation. (5) Pasion the center support bar int the spore tars correctly withthe large horton Sits Ten, (6) natal te tl attaching the seatbel o to the whelhonse, (7) install the bolts attaching the sport Bars tothe “Tighten the bots co 40 Nim (30 fos). 18) Return seat back to upright position, (0) stall che bolts attaching the sport bar co the cargo floor panel and install he enter carpet ‘Tighter the bolts to 40 Nim GO fis). 10) Ital the bots attaching the sport hae tothe brackets behind the door sirikers and ight to 68 Naw (90 ft Ion), tt) Postion Sie supports at the windshield and Install the bots ataching the side support bars to the veindshield fame. Tien the bolts co 32 Nin (ea set (U2) Ital the bale attaching the side support tars to the sport bars a ughten to 20 Naw (15M Toe). U3) Install the blts attaching the center support tae the sport bar ad tighten to 68 Nin 0M Tos {1A} Engage center suppor bar cover zipper (U5) Ital ehe speaker pads. (Refer ta 23 BODY! INTERIORSPORT BAR” SPEAKER POD INSTAL TATION) (10) Inca the a-pillar weathersirips (U7) Install the sum visoraReer a 28 - BODYIN TTERIORISUN VISOR" INSTALLATION)23-58 INTERIOR ‘SPORT BAR (Continued) (18) Instat the door opening feames. Refer vo 23 BODYINTERIORDOOR OPENING | FRAME INSTALLATION). (U9) Eomall ard top andar abt top. (Reler wo 23, BODVREMOVEABLE TOPIHARD TOP ~ INSTAL. LATION} oe (eter to 23 ~ BODYIREMOVEABLE ‘TOPSOFT TOP = INSTALLATION) A-PILLAR TRIM REMOVAL (0) Renee the apie tren sews. Fig 13) (2) Starting at the bowom, pul of the rim and INSTALLATION (H) Install the trim over the sports bar ond post tion the top (2) Press the bottom inte place ard instal the 1 An a Fig, 13 A-PILLAR TRIMw REAR HEADER TRIM REMOVAL 1) Disconnect the rear window defogger electrical connectors H equipped (2) Remove the Wiper motor ever and dsconnece the wiper mator electrical connector and” washer (@) Using arin stick €-4758 ar equivalent, spa rate che header trim end retainer lips tom the tp Fi 15) (f) Pull the wire harnesees and water hose INSTALLATION () Route the wire harness and washer hose "(2h instal the header tc and seat de retaining ‘pe fay 1 Conmect the wiper motor elerial and the washer hine connection (a) Conmect the tear window deowger elected connectors equipped. ig. 15 REAR HEADER TRIM WINDSHIELD HEADER REMOVAL (1) Poston both sun visors out fate the retaining clips and remove the tm fon ‘echind the pillar crim ponets Fig. 16 WINDSHIELD HEADER MOLOING INSTALLATION (0 Install the windshield header trim and position the end tabs behind the apilartri, (2) Seat the retaining lp fli23-60 INTERIOR SPORT BAR - SPEAKER POD REMOVAL (0) On vehicles eqlpped eth o sf op, unzip the (@)'On vencles equipped wth @ hard top, unctip the windshield clamps, 3) Rempve the belts onside ofthe top next tthe pl and loser Ue opposite side bots (Refer 1023, BODYIREMOVEABLE TOPHARD "TOP. REMOVAL) (U) Lit ap the se of the tap to gin acess to the “o) Rermave the two belts securing the pr tthe sport bar 1 (6) Separate the pod guide pln from the sport bar ‘and dnconnect the ekerkal connector INSTALLATION (0) Connece the pa electrical connector an instal te pox ont the gute pin (2) dnstll the Bolts and tighten to 68 Nm (0 Ios) 13) On vehicles equipped with hard top. instal the hardtop. [Refer to. 23"- BODYIREMOVABLE TOPHARD TOP INSTALLATION) (a) On vehicles equipped with a sft top, xp up the side panelu amt ees PAINT ‘waur oF cowrems i noe a ae ieee ee ee mess ant e@ PAINT PAINT CODE SPECIFICATIONS - PANT CODES Descriprion plied ee bee ee atacand os EXTERIOR COLOR [ DAMLERGHRYSLER | S\METY CERTIFICATION LABEL DESCIND Fata Po Tat eee eee ae oe 7 Soe toraae aoe — BASECOATICLEARCOAT ee = Baseci Descrirron INTERIOR COLORS ‘primer ts called basecoat. The clearcoat protects the TERORCOOR aR] hh cone ROTO zi EXTERIOR HARD AND SOFT TOP COLORS EXTERIOR WARD TOP ‘COLORS ‘coDe Black Tox Dark Rha Ze ‘DAINILERCHRYSLER