Service Procedure
1. Apply the parking brake and move the shifter lever to its full rearward position.2. Record the preset radio stations, then disconnect the battery negative cable.
3. Insert a small screwdriver into the defroster grille and gently pry the grille out of the instrument panel (I/P) (Figure 1).
4. Remove the instrument cluster bezel:
a. Contour models:
^ Remove the name plate or clock and disconnect the electrical connector, if equipped
^ Remove the screws securing the headlamp switch panel, then remove the panel and disconnect the electrical connectors
^ Remove the heated rear window switch panel by reaching through the headlamp switch panel opening and pushing it out from the inside of the I/P. Then disconnect the electrical connector
b. Mystique models:
^ Remove the three (3) bezel screw covers along the bottom of the cluster bezel
c. Both models:
^ Remove the screws attaching the bezel to the I/P
^ Remove the cluster bezel
5. Remove the right and left side A-pillar trim panels.
6. Remove the right and left hand instrument panel (I/P) main mounting bolt covers. Then remove the main mounting bolts (Figure 2).
7. Remove the four (4) bolts securing the driver-side instrument panel lower panel to the I/P, remove the courtesy lamp from the panel and remove the panel from the vehicle.
8. Remove the two (2) left hand center retaining bolts (Figure 3).
9. Remove the four (4) bolts securing the steering column to the I/P. Carefully pull the steering column toward the driver seat to disengage the mounting tab, and rest it on the driver seat (Figure 4). To prevent any possible damage, place a soft cloth over the steering wheel and steering column upper cover.
10. Open the glove box and mark the edge of the glove box opening with masking tape. This is done to make sure that when the rivets are installed, they will be below the glove box opening (Figure 5).
11. Remove the glove box from the vehicle.
^ Open the glove box to its fullest extent by depressing the tabs on each side Using a gentle left-to-right rocking motion, pull the glove box away from the I/P
12. Remove the passenger vent duct through the glove box opening.
13. Remove the two (2) right hand center retaining bolts (Figure 6).
14. Remove the two (2) upper I/P retaining nuts through the glove box opening (Figure 7).
CAUTION
DO NOT PULL THE lip OUT MORE THAN 15 CM (6 IN.) TO AVOID ANY POSSIBLE DAMAGE TO WIRE HARNESSES, VACUUM HOSES OR CABLES.
CAUTION
TO PREVENT ANY POSSIBLE DAMAGE, PLACE A SOFT CLOTH OVER THE SHIFTER LEVER.
15. Gently pull the I/P away from the windshield approximately 10-15 cm (4-6 in.).
CAUTION
DO NOT DAMAGE THE VINYL MATERIAL AROUND THE DEFROSTER DUCT OPENING WHILE SCRAPING THE SUBSTRATE MATERIAL FROM THE DEFROSTER DUCT OPENING.
NOTE
THE I/P VINYL MATERIAL MAY BE DELAMINATED SEVERELY ENOUGH TO INTERFERE WITH DEFROSTER COVER INSTALLATION. IF SO, INSTALL ONE OR MORE U-CLIPS TO PROPERLY FIT THE DEFROSTER COVER IN PLACE. IF U-CLIP INSTALLATION IS NECESSARY, YOU MAY ALSO NEED TO TRIM EXCESS BLACK SUBSTRATE MATERIAL FROM THE DEFROSTER DUCT OPENINGS. IF THE VINYL MATERIAL DOES NOT INTERFERE WITH COVER INSTALLATION, THEN U-CLIP INSTALLATION AND TRIMMING OF THE DEFROSTER DUCT OPENING IS NOT NECESSARY.
NOTE
INSERT SHOP TOWELS INTO THE TWO (2) CENTER DEFROSTER DUCTS TO PREVENT ANY DEBRIS FROM FALLING INTO THE HEATER CORE HOUSING.
NOTE
IT IS ACCEPTABLE FOR THE VINYL MATERIAL TO OVERLAP THE EDGE OF THE SUBSTRATE MATERIAL. IT IS NOT ACCEPTABLE FOR THE SUBSTRATE TO EXTEND BEYOND THE VINYL.
NOTE
A UTILITY KNIFE OR RAZOR-TYPE KNIFE IS NOT SUITABLE FOR SCRAPING THE SUBSTRATE. A STIFF-BLADED POCKET KNIFE WITH A LOCKING BLADE OR A LINOLEUM CUTTER IS RECOMMENDED.
16. Using a stiff knife, scrape any excess black substrate material or substrate flashing from along the inside edge of the defroster duct openings. Make sure the substrate is scraped back even to or just past the vinyl material (Figure 8).
NOTE
BE SURE TO INSTALL ALL U-CLIPS BEFORE INSTALLING THE EDGE TRIM MOLDING ON THE FRONT OF THE UP. THIS WILL MAKE MOLDING INSTALLATION EASIER. MAKE SURE SHOP TOWELS ARE INSERTED INTO THE TWO (2) CENTER DEFROSTER DUCTS TO PREVENT ANY U-CLIPS FROM FALLING INTO THE HEATER CORE HOUSING.
17. Install the U-clips as follows:
^ Be sure the clips you are using are the segmented type as in Figure 9, View A
^ Obtain the necessary U-clips from the repair kit. Using segmented U-clips, bend them slightly to match the curve of the defroster duct opening. Installing U-clips in the outermost defroster duct openings, make sure to install them flush against the opening support as indicated in Figure 9, View B
^ Position the U-clips in the defroster duct opening as indicated in Figure 9, View C
^ Snap the U-clips into place by "rolling" them around the edge of the defroster duct opening as indicated in Figure 9, View D
NOTE
DO NOT INSTALL THE GRILLE AT THIS TIME THIS STEP IS ONLY A TEST FIT.
18. Test fit the new defroster grille into the defroster grille opening. If the defroster grille is too long or does not fit properly, trim the ends of the grille to allow proper fit (Figure 10).
NOTE
THERE ARE SEVEN (7) DEFROSTER DUCT OPENING SUPPORTS. THREE (3) HAVE HOLES, FOUR (4) DO NOT.
19. Trim the vinyl material at each defroster duct opening support that has a hole in it so the retainer clips installed in Step 20 will not overlap the vinyl material (Figure 11).
20. Install one (1) retainer clip into each of the three (3) defroster duct opening supports with holes (Figure 12).
21. If necessary, clean any debris from the defroster duct, then remove the shop towels from the defroster ducts.
CAUTION
MAKE SURE THE SHOP TOWELS ARE REMOVED FROM THE DEFROSTER DUCT OPENINGS BEFORE INSTALLING THE NEW DEFROSTER GRILLE.
22. Working from the driver side toward the passenger side, install the new defroster grille by first inserting the forward edge firmly into place and then inserting the rearward edge.
23. Inspect the molding before installing it onto the I/P. Make sure the flock tape is on the lip seal side and wraps around the forward edge as shown (Figure 13). If the flock tape is not installed in this fashion, reposition as necessary.
CAUTION
THE MOLDING MUST BE INSTALLED ALONG THE LEADING EDGE OF THE I/P BEGINNING AT THE DRIVER SIDE, NOT IN THE CENTER. THE MOLDING MUST ALSO BE INSTALLED WITH THE LIP SEAL ON THE BOTTOM AND MUST BE FULLY SEATED AGAINST THE LEADING EDGE OF THE I/P. FAILURE TO INSTALL THE MOLDING IN THIS MANNER WILL RESULT IN AN IMPROPER FIT AND A POOR APPEARANCE.
NOTE
TO MAKE INSTALLATION OF THE MOLDING EASIER, MAKE SURE THE I/P IS PULLED AWAY FROM THE BULKHEAD AS FAR AS POSSIBLE WITHOUT DAMAGING ANY WIRE HARNESSES, VACUUM HOSES OR CABLES.
24. Install the molding as follows:
^ Beginning at the driver side of the I/P, position the rearward edge of molding so it is flush with the side of the I/P. Installed correctly, the forward edge of the molding will hang over the I/P about 10 - 13 mm (3/8 - 1/2 in.) (Figure 13)
^ Work the molding into place along the length of the I/P toward the passenger side, making sure to fully seat it as you go
NOTE
STEPS 25-27 ARE FOR DEFROSTER COVER INSTALLATION.
25. Position the defroster cover onto the I/P over the defroster grille.
CAUTION
ONLY USE A 4.7 MM (3/16 IN.) DRILL BIT WHILE INSTALLING THE DEFROSTER COVER. DO NOT ALLOW THE DRILL BIT TO MOVE FROM SIDE TO SIDE WHILE DRILLING. THE HOLE FOR THE RIVET MUST NOT BE LARGER THAN 4.7 MM (3/16 IN.).
NOTE
THE DEFROSTER COVER COMES WITH SIX (6) PRE-DRILLED RIVET HOLES. USE THESE HOLES AS A GUIDE TO DRILL RIVET HOLES INTO THE DEFROSTER DUCT OPENING SUPPORTS.
NOTE
MAKE SURE THE RIVETS ARE FULLY SEATED AGAINST THE DEFROSTER COVER, AND MAKE SURE TO PRESS THE RIVET GUN FIRMLY AGAINST THE DEFROSTER COVER WHILE FASTENING THE RIVETS.
26. While holding the defroster cover in place with one hand, drill out one of the center rivet holes using the pre-drilled hole in the defroster cover as a guide. Make sure to drill straight through the defroster duct opening support. Position one (1) rivet into the drilled hole, but do not fasten it at this time. Drill out the other center rivet hole, making sure to go straight through the support beneath it, and then position and fasten one (1) rivet in the drilled hole. Fasten the first rivet and then continue working from the center toward the outside, drilling each hole and installing rivets one at a time.
27. Touch up any rivet heads as necessary with black touch-up paint, or equivalent, to cover any silver/metallic color that may be showing.
CAUTION
MAKE SURE THERE ARE NO WIRE HARNESSES OR VACUUM LINES BETWEEN THE I/P AND ITS MOUNTING FRAME BEFORE POSITIONING THE I/P AND INSTALLING THE FASTENERS.
28. Position the I/P onto its mounting frame.
29. Install the right and left hand I/P main mounting bolts, then install the main mounting bolt covers.
30. Install the two (2) right hand center retaining bolts and the two (2) upper I/P retaining nuts through the glove box opening.
31. Install the passenger vent duct through the glove box opening.
NOTE
THE RIVET HOLES THAT ARE GOING TO BE DRILLED MUST BE SPACED APPROXIMATELY 51 MM (2 IN.) APART AND MUST BE PLACED BELOW THE TAPE THAT WAS APPLIED EARLIER IN THIS PROCEDURE (FIGURE 14).
32. On each side of the bottom of the glove box opening, measure out and place two (2) marks to indicate where the rivet holes will be drilled (Figure 14).
CAUTION
DO NOT EXCEED A DEPTH OF 10 MM (3/8 IN.) WHEN DRILLING THE HOLES. YOU MUST USE A DRILL STOP OR APPLY TAPE 10 MM (3/8 IN.) FROM THE TIP OF THE DRILL BIT TO PREVENT IT FROM DRILLING TOO FAR INTO THE I/P.
33. Using a 3.2 mm (1/8 in.) drill bit, drill one (1) hole in each 6f the four (4) locations marked (Figure 14).
34. Using a commercially available pop rivet gun, install one (1) supplied rivet in each hole that was drilled into the bottom of the glove box opening.
CAUTION
ON MOST VEHICLES, THE RIVET HOLES MUST BE DRILLED 76 MM (3 IN.) APART AND 19 MM (3/4 IN.) IN FROM THE CLUSTER OPENING LEDGE. FOR VEHICLES THAT HAVE LESS THAN 19 MM (3/4 IN.) OF VINYL MATERIAL OVERLAPPING THE CLUSTER OPENING, THE HOLE MUST BE DRILLED NO CLOSER THAN 5 MM (3/16 IN.) TO THE END OF THE VINYL MATERIAL. IF THE HOLES ARE DRILLED IN ANY PLACE BUT THE DESCRIBED LOCATIONS, THE HEADS OF THE RIVETS WILL EITHER TEAR THROUGH THE VINYL MATERIAL OR WILL BE VISIBLE AFTER CLUSTER INSTALLATION.
35. From below the instrument cluster opening ledge of the I/P, measure out and place seven (7) marks to indicate where the rivet holes will be drilled. Place the first mark directly above the exact center of the cluster. From this point, measure 76 mm (3 in.) out on both sides to locate the remaining holes (Figure 15).
CAUTION
TO PREVENT DRILLING THROUGH THE TOP OF THE I/P, A DRILL STOP MUST BE USED WHEN DRILLING THE RIVET PLACEMENT HOLES INTO THE INSTRUMENT CLUSTER OPENING LEDGE. THE DRILL BIT MUST NOT GO FURTHER THAN 10 MM (3/8 IN.) INTO THE I/P.
NOTE
INSTRUMENT PANELS THAT ARE DAMAGED DUE TO "DRILL-THROUGH" ARE NOT WARRANTABLE. IF A MECHANICAL DRILL STOP IS NOT AVAILABLE, ONE CAN BE MADE BY EITHER WRAPPING AN ABUNDANCE OF ELECTRICAL TAPE AROUND THE BIT AT THE CORRECT DEPTH OF 10 MM (3/8 IN), OR INSTALLING A SHORT PIECE OF VACUUM HOSE HELD IN PLACE BY TAPE AT THE CORRECT DEPTH.
CAUTION
FAILURE TO DRILL STRAIGHT THROUGH THE VINYL AND SUBSTRATE MAY CAUSE THE RIVETS TO PULL THROUGH THE VINYL MATERIAL.
CAUTION
ONLY USE CLAMPS THAT HAVE RUBBER OR PLASTIC-COATED JAWS TO PREVENT DAMAGING THE VINYL I/P SURFACE.
36. Install a drill stop onto the drill bit 10 mm (3/8 in.) from the tip. As you drill each hole, hold the vinyl flush against the substrate material, either by hand or by using a spring clamp with protective-coated jaws (Figure 16). Using a 3.2 mm (1/8 in.) drill bit, drill seven (7) holes into the bottom of the instrument cluster opening ledge of the I/P.
37. Using a commercially available pop rivet gun, install one (1) supplied rivet in each hole that was drilled into the I/P.
38. Install the instrument cluster bezel and all screws that secure the bezel.
a. Contour models:
^ Install the name plate and, if equipped, connect the electrical connector and install the clock
^ Connect the electrical connectors on the heated rear window switch and the headlamp switch, and install both switch panels into the I/P
b. Mystique models:
^ Install the three (3) bezel screw covers along the bottom of the cluster bezel
39. Position the steering column into the I/P by engaging the mounting tab, then install the four (4) bolts securing it to the I/P. Tighten the bolts to 24 N.m (18 Lb-ft).
40. Install the two (2) left hand center retaining bolts.
41. Install the courtesy lamp into position on the driver side instrument panel lower panel, position the panel onto the I/P, and install the four (4) bolts securing it to the I/P.
42. Remove the tape applied earlier in this procedure, then install the glove box into its original position in the I/P.
43. Install the right and left side A-pillar trim panels.
44. Connect the battery negative cable and program the preset radio stations.
45. Move the shifter lever into the PARK position and release the parking brake.