Installation

1. Install module into vehicle.
2. Install HVAC module to front of dash and hand start bolts.

NOTE: A new filter housing seal must be used whenever the filter housing is removed to prevent water from leaking into module.




3. Remove filter housing seal using a small flat blade screwdriver.
4. Install new filter housing seal.




5. Install filter housing and screws.

Torque: 3.5 N.m (31 in-lbs)




6. Tighten HVAC module to front of dash bolts.

Torque: 4.5 N.m (40 in-lbs)

7. Install condensate drain tube and bolt.

Torque: 3.5 N.m (31 in-lbs)




8. Install cabin air filter paying special attention to air flow direction indicator.
9. Rotate locking tabs to secure air filter in place.




10. Install cowl screen and fasteners.

Torque: 1 N.m (9 in-lbs)

11. Close filter access door.




12. Install wiper arm assemblies.

Torque: 20 N.m (15 ft-lbs)




13. Install beam to steering column braces. Using a large screwdriver, pry steering column braces apart to clear beam studs and slide beam forward to locate studs into holes.

NOTE:
^ Open drivers side door completely and install protective covering on door inner hinge area to prevent damage to paint.
^ On wagons, the rear washer supply hose is routed through the drivers side A-pillar. Use care not to pinch or damage hose.




14. Install cockpit assembly aid J 43894 into A-pillar beam bolt holes. Tool flange should fit tight to A-pillar surface when completely installed. This tool is needed to prevent accidentally dropping bolt inside A-pillar.




15. Install upper and lower inner beam bolts.

Torque: 20 N.m (15 ft-lbs)

16. Remove cockpit assembly aid J 43894.




17. Install upper and lower outer beam bolts.

Torque: 7 N.m (62 in-lbs)




18. Install black plastic bolt caps.
19. Repeat beam bolt installation procedure on passenger's side.




20. Install I/P beam to steering column brace nuts.

Torque: 20 N.m (15 ft-lbs)




21. Install I/P harness rosebud connectors to I/P beam.




22. Connect I/P harness electrical harness to module harness.




23. Position I/P to vehicle.
24. Loosely install three upper I/P fasteners at W/S defroster location.
25. Loosely install I/P fasteners at cluster.
26. Loosely install I/P fasteners at glove compartment.
27. Loosely install I/P fasteners at left side to beam.
28. Loosely install I/P fasteners at end brackets.
29. Torque all fasteners.

Torque: 20 N.m (26 ft-lbs)




30. Secure I/P harness to I/P at locations where clips were removed.




31. Attach electrical harness to I/P at center outlet location.




32. Install cluster harness to I/P ensuring that harness is secured into I/P retainer.




33. Install cluster into I/P housing ensuring that the cluster harness is connected. Install and tighten fasteners.

Torque: 2.3 N.m (22 in-lbs)




34. Install cluster trim plate with fasteners.

Torque: 2.2 N.m (22 in-lbs)




35. Install steering column trim cover and attachment fasteners.

Torque: 4 N.m (35 in-lbs)




36. Position I/P filler to instrument panel and push at attaching clip locations to secure bolster to I/P
37. Reposition steering wheel.




38. Connect left side A/C outlet switch harness and install A/C outlet with fastener.

Torque: 2.5 N.m (22 in-lbs)




39. Snap hood release handle bracket into I/P




40. Install diagnostic connection by snapping into bracket.




41. Install left side HVAC lower outlet with retainer.




42. Install HVAC control to the I/P and install fasteners.
43. Torque fasteners.

Torque: 2.5 N.m (22 in-lbs)




44. Connect radio ground strap spade terminal, electrical connector(s), and antenna to rear of radio.
45. Install radio by sliding it into the guides on the instrument panel.
46. Install and tighten screws.

Torque: 2.5 N.m (22 in-lbs)




47. Connect center trim plate switch harnesses to switches and snap center trim plate into I/P.




48. Snap W/S defroster grille into I/P




49. Install glove compartment bin partially into opening.
50. Secure BCM module to glove compartment bin slots.




51. Route glove box lamp wiring harness through lamp opening and connect glove compartment lamp wiring harness to glove compartment lamp.
52. Snap lamp into glove compartment bin.




53. Install glove compartment bin to I/P with fasteners.

Torque: 2.5 N.m (22 in-lbs)




54. Install heater outlet with retainer to glove compartment bin.




55. Install lower dash insulator with retainers.
56. Function glove compartment lamp and glove compartment door to assure proper operation.




57. Install glove compartment door with fasteners.

Torque: 2 N.m (18 in-lbs)




58. Install I/P bracket.

Torque: 20 N.m (15 ft-lbs)




59. Position console into vehicle. Route shifter/PRNDL boot through console opening.
60. Install console front fasteners.

Torque: 2.5 N.m (22 in-lbs)

61. Move front seats forward and install console rear fasteners.

Torque: 2.5 N.m (22 in-lbs)

On automatic transmissions




62. Snap PRNDL cover into console opening.

On 5-speed transmissions




63. Snap shifter boot into console opening.
64. Connect console wiring harness to main body harness.




65. Snap console front tray into console.

On power windows




66. Connect power window harness to power window switch and snap switch into place.




67. Snap park brake boot into place.




68. Install console extensions.




69. Install steering column trim cover and attachment fasteners.

Torque: 4 N.m (35 in-lbs)




70. Install ignition switch by pushing the switch in and turning to run position.




71. Remove yellow tab or tape from SIR Coil assembly.
72. Route wiring through steering wheel and install steering wheel onto steering shaft noting orientation notch that locates steering wheel in correct position.

IMPORTANT: A new steering wheel attachment nut must be used.

73. Install new steering wheel attachment nut.

Torque: 40 N.m (30 ft-lbs)




74. Connect cruise control (if equipped) switch connectors and attach harness to wheel.




75. Connect inflator module wiring harness and install harness integral connector lock device.
76. Install inflator module into steering wheel. Be sure to seat all four attachment points.
77. Enable the SIR system. (Refer to "Enabling the SIR System" procedure.) Disabling and Enabling the SIR System




78. Install heater inlet quick connect to heater inlet pipe (closest to driver's side). Holding quick connect by black collar, slide onto heater pipe. When quick connect engages heater pipe bead, collar will slide towards front of dash and lock into position.




79. Verify proper engagement of quick connect by attempting to pull hose off heater pipe.




80. Install heater outlet quick connect to heater outlet pipe (closest to passenger's side). Holding quick connect by white collar, slide onto heater pipe. When quick connect engages heater pipe bead, collar will slide towards front of dash and lock into position.
81. Verify proper engagement of quick connect by attempting to pull hose off heater pipe.




82. Remove protective cap from TXV
83. Thoroughly clean the O-ring surfaces of the TXV
84. Remove cap and install new O-rings to suction/liquid line assembly block.
85. Lubricate the O-rings with clean mineral oil.
86. Install suction/liquid line assembly block to TXV
87. Install suction/liquid line assembly to TXV bolt.

Torque: 7 N.m (62 in-lbs)




88. Rinse off any coolant that was spilled in engine compartment.
89. Connect negative battery cable.

Torque: 17 N.m (157 in-lbs)

90. Fill cooling system - see "Coolant Replacement" in Cooling System.
91. Evacuate, charge, and leak check the A/C system.