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Assembly-Instrument Panel: Removal

WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT CLASSIFICATION SYSTEM, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE OCCUPANT RESTRAINT CONTROLLER CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT.
CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the SUPPLEMENTAL RESTRAINTS VERIFICATION TEST before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules.
Fig 1: COLUMN OPENING COVER SCREW
GC0010569Courtesy of DAIMLERCHRYSLER CORP.
  1. Before proceeding with the following repair procedure, review all warnings and cautions. (Refer to BODY/INSTRUMENT PANEL - WARNING) 
  2. Disconnect and isolate battery negative cable.
  3. Using a trim stick C-4755 or equivalent, remove the left door sill trim cover.
  4. Remove the screw and remove the left cowl trim cover.
  5. Remove the left instrument panel end cap.
  6. Remove the two screws (1) and remove the steering column opening cover (2).
    Fig 2: RELEASE HANDLE
    GC0010502Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the screws (5) and position aside the hood release handle (2).
    Fig 3: COLUMN REINFORCEMENT
    GC0010570Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the four screws (2) and remove the steering column opening reinforcement (1).
    Fig 4: SHROUDS
    GC0010576Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove the steering column tilt lever.
  10. Remove the upper (1) and lower (3) column shrouds.
    Fig 5: HARNESS CONNECTORS
    GC0010577Courtesy of DAIMLERCHRYSLER CORP.
  11. Disconnect the wiring harness connectors (1) to the column.
  12. Remove the shift cable from the column shift lever actuator. (Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC/GEAR SHIFT CABLE - REMOVAL)
  13. Release the shift cable from the column bracket and remove it from the bracket.
  14. Remove the SKIM module in order to disconnect the electrical connector.
    Fig 6: UPPER COUPLING SHAFT AND PINCH BOLT
    GC0010579Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the upper steering shaft coupler bolt (2) and slide the shaft (3) down.
    Fig 7: SHROUDS
    GC0010576Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the brake light switch (5) and discard (Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL) .
    Fig 8: COLUMN
    GC0010578Courtesy of DAIMLERCHRYSLER CORP.
  17. Remove the four steering column mounting nuts (3).
  18. Lower the column from the mounting studs (1).
  19. Remove the steering column assembly (2) from the vehicle.
    Fig 9: MAG BRACKET BOLTS
    GC0010571Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove the pedal support bracket bolts.
    Fig 10: RELEASE ROD
    GC0010580Courtesy of DAIMLERCHRYSLER CORP.
  21. Disengage the release rod (1) from the arm on the pedal assembly.
    Fig 11: ELECTRICAL CONNECTORS
    GC0010575Courtesy of DAIMLERCHRYSLER CORP.
  22. Disconnect the electrical connectors (1, 2 and 3) from the fuse block.
  23. Remove the bolt and remove the ground wire (4).
  24. Open the trim covers in the drivers side a-pillar grab handle and remove the bolts.
  25. Remove the a-pillar trim panel.
  26. Remove the floor console. (Refer to BODY/INTERIOR/FLOOR CONSOLE - REMOVAL) 
    Fig 12: REMOVE/INSTALL OCCUPANT RESTRAINT CONTROLLER
    GC0010581Courtesy of DAIMLERCHRYSLER CORP.
  27. Disconnect the two body wire harness connectors (1) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector.
    Fig 13: CENTER HARNESS
    GC0010583Courtesy of DAIMLERCHRYSLER CORP.
  28. Position the carpet aside and remove the center harness screws (1). Pull instrument panel wiring harness (2) from under the carpet.
    Fig 14: CENTER SUPPORT BOLTS
    GC0010572Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove the center support bolts.
  30. Remove the drivers seat. (Refer to BODY/SEATS/SEAT - REMOVAL) 
  31. Remove the drivers side floor duct.
    Fig 15: SIDE SUPPORT BOLTS
    GC0010573Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove the drivers side support bolts.
    Fig 16: SIDE SUPPORT BOLTS
    GC0010573Courtesy of DAIMLERCHRYSLER CORP.
  33. Remove the right instrument panel end cap.
  34. Remove the passenger side support bolts.
    NOTE: Drivers side shown in Fig 16, passenger side similar.
  35. Using a trim stick C-4755 or equivalent, remove the right door sill trim cover.
  36. Remove the screw and remove the right cowl trim cover.
    37. Fig 17: AMPLIFIER
    GC0010582Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove the bolts and remove the amplifier.
  38. Disconnect the amplifier and antenna electrical connectors.
    Fig 18: PASSENGER HARNESS
    GC0010584Courtesy of DAIMLERCHRYSLER CORP.
  39. Remove the harness bolt (1) and the ground wire(3) bolt (2).
  40. Remove the passenger side rear floor duct.
    Fig 19: DEFROSTER GRILLE
    GC0010568Courtesy of DAIMLERCHRYSLER CORP.
  41. Open the trim covers in the passenger side a-pillar grab handle and remove the bolts.
  42. Remove the a-pillar trim panel.
  43. Using a trim stick C-4755 or equivalent, remove the instrument panel defroster grille.
  44. Disconnect the sensor electrical connector (2).
    Fig 20: FENCELINE BOLTS
    GC0010574Courtesy of DAIMLERCHRYSLER CORP.
  45. Remove the four fenceline bolts (2).
  46. Lift the instrument panel assembly (3) off the side support pins (1) and remove assembly through the drivers door.
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