hood open CHRYSLER CARAVAN 2002 Owner's Manual

8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch...................8W-15-7, 8
A/C- Heater Control....................8W-15-9, 11
Adjustable Pedals Module..................8W-15-17
Airbag Control Module....................8W-15-12
Auto Temp Control.......................8W-15-9
Automatic Day/Night Mirror.................8W-15-21
Autostick Switch........................8W-15-10
Back-Up Lamp Switch....................8W-15-3, 7
Battery.............................8W-15-2, 3
Body Control Module.....................8W-15-22
Brake Fluid Level Switch...................8W-15-17
Brake Lamp Switch......................8W-15-17
Cabin Heater Assist.......................8W-15-8
Center Dome Lamp......................8W-15-21
Center High Mounted Stop Lamp..............8W-15-26
Clutch Pedal Upstop Switch.................8W-15-18
Controller Antilock Brake..................8W-15-2, 3
Crank Case Ventilation Heater................8W-15-8
Crankshaft Position Sensor..................8W-15-3
Data Link Connector..................8W-15-2, 3, 17
Dosing Pump...........................8W-15-8
Driver Door Courtesy Lamp...............8W-15-15, 20
Driver Door Lock Switch.................8W-15-15, 20
Driver Heated Seat Cushion.................8W-15-11
Driver Heated Seat Module.................8W-15-11
Driver Power Seat Switch..................8W-15-11
Driver Power Window Switch..............8W-15-15, 20
Engine Control Module.....................8W-15-3
Floor Console Lamp......................8W-15-25
Floor Console Power Outlet.................8W-15-25
Front Blower Module.....................8W-15-11
Front Cigar Lighter.......................8W-15-9
Front Control Module..................8W-15-7, 8, 18
Front Reading Lamps/Switch................8W-15-21
Fuel Heater...........................8W-15-25
Fuel Heater Relay........................8W-15-3
Fuel Pump Module.......................8W-15-25
G100..............................8W-15-2, 3
G101..............................8W-15-2, 3
G102.............................8W-15-4, 5, 6
G103..............................8W-15-7, 8
G200...........................8W-15-9, 10, 11
G201...............................8W-15-12
G202...............................8W-15-13
G300........................8W-15-14, 16, 17, 18
G301........................8W-15-19, 20, 21, 22
G302...........................8W-15-23, 24, 25
G400.............................8W-15-25, 26
Glove Box Lamp........................8W-15-10
Halo Lamp............................8W-15-10
Headlamp Switch........................8W-15-9
Headlamp Washer Pump Motor................8W-15-6
High Note Horn........................8W-15-5, 6
Hood Ajar Switch........................8W-15-18
Instrument Cluster.......................8W-15-9
Instrument Panel Switch Bank...............8W-15-10
Integrated Power Module............8W-15-2, 3, 7, 8, 18
Left B-Pillar Switch......................8W-15-17
Left Cinch/Release Motor...................8W-15-14
Left Combination Relay....................8W-15-24
Left Cylinder Lock Switch................8W-15-15, 16
Left Door Speaker.......................8W-15-13
Left Fog Lamp........................8W-15-5, 6
Left Front Door Ajar Switch.................8W-15-16
Left Front Door Lock Motor/Ajar Switch.......8W-15-15, 16
Left Front Park/Turn Signal Lamp..............8W-15-5
Left Full Open Switch.....................8W-15-14
Left Headlamp.........................8W-15-18
Left Headlamp Leveling Motor................8W-15-6
Left High Beam Lamp....................8W-15-18
Left Liftgate Flood Lamp...................8W-15-26
Left Low Beam Lamp.....................8W-15-18
Left Mid Reading Lamp....................8W-15-21
Left Park Lamp.........................8W-15-18
Left Power Mirror.......................8W-15-10
Left Rear Lamp Assembly..................8W-15-24
Left Rear Reading Lamp...................8W-15-21
Left Side Impact Airbag Control Module.........8W-15-12
Left Sliding Door Control Module..............8W-15-14
Left Sliding Door Latch Sensing Switch..........8W-15-14
Left Sliding Door Lock Motor................8W-15-14Component PageLeft Sliding Door Lock Motor/Ajar Switch.........8W-15-14
Left Sliding Door Motor....................8W-15-14
Left Stop/Turn Signal Relay.................8W-15-24
Left Turn Signal Lamp....................8W-15-18
Left Visor/Vanity Lamp....................8W-15-21
License Lamp........................8W-15-23, 26
Lift Pump Motor........................8W-15-25
Liftgate Ajar Switch......................8W-15-26
Liftgate Cinch/Release Motor................8W-15-23
Liftgate Cylinder Lock Switch................8W-15-26
Liftgate Right Pinch Sensor.................8W-15-23
Low Note Horn........................8W-15-5, 6
Memory Seat/Mirror Module.................8W-15-11
Overhead Console.......................8W-15-21
Oxygen Sensor 1/2 Downstream...............8W-15-7
Park/Neutral Position Switch.................8W-15-7
Passenger Door Courtesy Lamp............8W-15-16, 20
Passenger Door Lock Switch..............8W-15-16, 20
Passenger Heated Seat Module...............8W-15-22
Passenger Power Seat Switch................8W-15-22
Passenger Power Window Switch............8W-15-16, 20
Power Folding Mirror Switch................8W-15-11
Power Liftgate Module....................8W-15-23
Power Liftgate Motor.....................8W-15-23
Power Mirror Switch......................8W-15-11
Power Outlet...........................8W-15-9
Power Window Switch.....................8W-15-15
Powertrain Control Module..................8W-15-2
Radiator Fan No. 1.......................8W-15-4
Radiator Fan No. 2.......................8W-15-4
Radiator Fan Relay.......................8W-15-4
Radiator Fan Relay No. 3...................8W-15-4
Radio...............................8W-15-13
Rear Auto Temp Control Switch...............8W-15-17
Rear Blower Front Control Switch.............8W-15-11
Rear Blower Motor Power Module...........8W-15-11, 25
Rear Blower Rear Control Switch..............8W-15-17
Rear Dome Lamp........................8W-15-21
Rear Power Outlet.......................8W-15-25
Rear Window Defogger Grid.................8W-15-26
Rear Wiper Motor.......................8W-15-26
Remote Keyless Entry Module................8W-15-10
Right B-Pillar Switch.....................8W-15-22
Right Cinch/Release Motor..................8W-15-19
Right Combination Relay...................8W-15-24
Right Cylinder Lock Switch.................8W-15-20
Right Door Speaker......................8W-15-13
Right Fog Lamp........................8W-15-5, 6
Right Front Door Ajar Switch................8W-15-20
Right Front Door Lock Motor/Ajar Switch.........8W-15-20
Right Front Park/Turn Signal Lamp.............8W-15-5
Right Full Open Switch....................8W-15-19
Right Headlamp........................8W-15-18
Right Headlamp Leveling Motor...............8W-15-6
Right High Beam Lamp....................8W-15-18
Right Liftgate Flood Lamp..................8W-15-26
Right Low Beam Lamp....................8W-15-18
Right Mid Reading Lamp...................8W-15-21
Right Park Lamp........................8W-15-18
Right Power Mirror......................8W-15-10
Right Rear Lamp Assembly.................8W-15-25
Right Rear Reading Lamp..................8W-15-21
Right Side Impact Airbag Control Module.........8W-15-12
Right Sliding Door Control Module.............8W-15-19
Right Sliding Door Latch Sensing Switch.........8W-15-19
Right Sliding Door Lock Motor...............8W-15-19
Right Sliding Door Lock Motor/Ajar Switch........8W-15-19
Right Sliding Door Motor...................8W-15-19
Right Stop/Turn Signal Relay................8W-15-24
Right Turn Signal Lamp...................8W-15-18
Right Visor/Vanity Lamp...................8W-15-21
Sentry Key Immobilizer Module...............8W-15-10
Speed Control Servo.......................8W-15-7
Traction Control Switch....................8W-15-10
Trailer Tow Connector.....................8W-15-24
Transmission Control Module.................8W-15-2
Transmission Control Relay..................8W-15-2
Transmission Range Sensor..................8W-15-7
Washer Fluid Level Switch.................8W-15-5, 6
Wiper Module..........................8W-15-17
RS8W-15 GROUND DISTRIBUTION8W-15-1
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Component Page
Glove Box Lamp.................... 8W-80-63
Glow Plug Relay (Diesel).............. 8W-80-63
Halo Lamp........................ 8W-80-63
Headlamp Switch................... 8W-80-64
Headlamp Washer Pump Motor
(Built-Up-Export)................. 8W-80-64
High Note Horn.................... 8W-80-64
Hood Ajar Switch................... 8W-80-64
Idle Air Control Motor (2.4L).......... 8W-80-64
Idle Air Control Motor (3.3L/3.8L)....... 8W-80-65
Ignition Coil (2.4L).................. 8W-80-65
Ignition Coil (3.3L/3.8L).............. 8W-80-65
Ignition Switch..................... 8W-80-65
Inlet Air Temperature Sensor.......... 8W-80-65
Input Speed Sensor (EATX)........... 8W-80-66
Instrument Cluster.................. 8W-80-66
Instrument Panel Switch Bank......... 8W-80-66
Integrated Power Module C1.......... 8W-80-67
Integrated Power Module C2.......... 8W-80-67
Integrated Power Module C3 (Diesel).... 8W-80-68
Integrated Power Module C3 (Gas)...... 8W-80-68
Integrated Power Module C4.......... 8W-80-69
Integrated Power Module C5.......... 8W-80-69
Integrated Power Module C6.......... 8W-80-69
Integrated Power Module C7.......... 8W-80-70
Integrated Power Module C8.......... 8W-80-70
Integrated Power Module C9.......... 8W-80-71
Knock Sensor (2.4L)................. 8W-80-71
Knock Sensor (3.3L/3.8L) (Except
Built-Up-Export).................. 8W-80-71
Leak Detection Pump (Except
Built-Up-Export).................. 8W-80-71
Left B-Pillar Switch (Power
Sliding Door)..................... 8W-80-72
Left Cinch/Release Motor (Power
Sliding Door)..................... 8W-80-72
Left Combination Relay (Trailer Tow).... 8W-80-72
Left Cylinder Lock Switch............. 8W-80-72
Left Door Speaker................... 8W-80-72
Left Fog Lamp (Built-Up-Export)....... 8W-80-73
Left Fog Lamp (Except
Built-Up-Export).................. 8W-80-73
Left Front Door Ajar Switch (Base)...... 8W-80-73
Left Front Door Lock Motor/Ajar Switch
(Except Base).................... 8W-80-73
Left Front Park/Turn Signal Lamp
(Except Built-Up-Export)........... 8W-80-73
Left Front Wheel Speed Sensor......... 8W-80-74
Left Full Open Switch
(Power Sliding Door)............... 8W-80-74
Left Headlamp (Except Built-Up-Export) . 8W-80-74
Left Headlamp Leveling Motor
(Built-Up-Export)................. 8W-80-74
Left High Beam Lamp
(Built-Up-Export)................. 8W-80-74Component Page
Left Instrument Panel Speaker......... 8W-80-75
Left Liftgate Flood Lamp............. 8W-80-75
Left Low Beam Lamp (Built-Up-Export) . . 8W-80-75
Left Mid Reading Lamp
(Premium/Luxury)................. 8W-80-75
Left Park Lamp (Built-Up-Export)...... 8W-80-75
Left Power Mirror................... 8W-80-76
Left Rear Lamp Assembly............. 8W-80-76
Left Rear Pillar Speaker.............. 8W-80-76
Left Rear Reading Lamp (Luxury)...... 8W-80-76
Left Rear Speaker................... 8W-80-77
Left Rear Vent Motor................ 8W-80-77
Left Rear Wheel Speed Sensor......... 8W-80-77
Left Remote Radio Switch............. 8W-80-77
Left Repeater Lamp (Built-Up-Export) . . . 8W-80-77
Left Seat Airbag.................... 8W-80-78
Left Side Impact Airbag Control Module . . 8W-80-78
Left Sliding Door Control Module C1
(Power Sliding Door)............... 8W-80-78
Left Sliding Door Control Module C2
(Power Sliding Door)............... 8W-80-78
Left Sliding Door Latch Sensing Switch
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door).............. 8W-80-79
Left Sliding Door Motor
(Power Sliding Door)............... 8W-80-79
Left Speed Control Switch............ 8W-80-79
Left Stop/Turn Signal Relay (Trailer Tow) . 8W-80-80
Left Turn Signal Lamp (Built-Up-Export) . 8W-80-80
Left Visor/Vanity Lamp
(Premium/Luxury)................. 8W-80-80
License Lamp (Manual Release)........ 8W-80-80
License Lamp (Power Liftgate)......... 8W-80-80
License Lamp (Power Release)......... 8W-80-81
Lift Pump Motor (Diesel)............. 8W-80-81
Liftgate Ajar Switch (Manual Release) . . . 8W-80-81
Liftgate Ajar Switch (Power Release).... 8W-80-81
Liftgate Cinch/Release Motor
(Power Liftgate).................. 8W-80-81
Liftgate Cylinder Lock Switch.......... 8W-80-82
Liftgate Left Pinch Sensor
(Power Liftgate).................. 8W-80-82
Liftgate Right Pinch Sensor
(Power Liftgate).................. 8W-80-82
Low Note Horn..................... 8W-80-82
Manifold Absolute Pressure Sensor
(Gas)........................... 8W-80-82
Mass Air Flow Sensor (Diesel)......... 8W-80-83
Memory Seat/Mirror Module C1........ 8W-80-83
Memory Seat/Mirror Module C2........ 8W-80-84
Memory Seat/Mirror Module C3........ 8W-80-84
Memory Seat/Mirror Module C4........ 8W-80-84
RS8W-80 CONNECTOR PIN-OUTS8W-80-3
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OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Open hood, remove oil fill cap.
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(4) Place a suitable drain pan under crankcase
drain (Fig. 101).
(5) Remove drain plug from crankcase (Fig. 101)
and allow oil to drain into pan. Inspect drain plug
threads for stretching or other damage. Replace
drain plug and gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
Fig. 100 Engine Oiling System
1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 7 - OUTER ROTOR
2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 - INNER ROTOR
3 - ROCKER SHAFT 9 - RELIEF VALVE
4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD
FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT
HEAD10 - OIL PAN
5 - ROCKER SHAFT TOWER 11 - OIL SCREEN
6 - CRANKSHAFT 12 - OIL PUMP CASE
9 - 138 ENGINE 3.3/3.8LRS
LUBRICATION (Continued)
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................4INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............9
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................10
INSTALLATION.........................12
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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DESCRIPTION - 2.5L DIESEL
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to a bracket on the engine manifold (Fig.
25).
OPERATION
The power steering fluid reservoir stores and sup-
plies power steering fluid for the power steering sys-
tem.
REMOVAL
REMOVAL - 2.4L ENGINE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Open retainer on side of reservoir and remove
cables from retainer.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir.
(5) Remove bolts and nut securing reservoir in
place.
(6) Remove reservoir.
REMOVAL - 3.3L/3.8L ENGINE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Open retainer on side of reservoir and remove
cables from retainer.(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).
(5) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).
(6) Remove bolts and nut securing reservoir in
place (Fig. 21).
(7) Remove reservoir.
REMOVAL - 2.5L DIESEL
(1) Open hood.
(2) Remove engine cover.
(3) Remove the filler cap from remote power steer-
ing fluid reservoir.
(4) Siphon as much fluid as possible from the fluid
reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 25).
Fig. 24 Power Steering Fluid Reservoir (Typical)
Fig. 25 Reservoir And Hoses - 2.5L Diesel
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
19 - 52 PUMPRS
RESERVOIR - POWER STEERING FLUID (Continued)
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COWL GRILLE
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove four (4) screws securing cowl cover to
wiper module (Fig. 6).
(3) Disengage quarter turn fasteners at outboard
ends of cowl grill from body.
(4) Release hood latch and open hood.
CAUTION: To prevent hood scratching of cowl grille
before removal, cover outboard exterior ends of
cowl grille with masking tape or equivalent method.
NOTE: Do not over bend cowl grille during removal.
Bend cowl grille just enough to clear top of wiper
pivot shaft and bottom rear corner of hood.
(5) Remove cowl grill by raising above driver side
wiper pivot shaft and swinging away towards engine
compartment. The cowl grille will need to be bent on
outboard end to clear simultaneously top of wiper
pivot shaft and bottom corner of hood.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 7).
(7) Disconnect washer hose in line connector.
(8) Disconnect washer hose and grommet from
hole in wiper module and pull out.
(9) Remove cowl grille by raising over opposite
wiper pivot shaft and removing away from vehicle.
(10) Remove cowl cover from vehicle.
INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Star all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.
(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
(7) Tighten screw to 1.2 N´m (11 in. lbs.) torque.
(8) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(9) Check for proper spray pattern from washer
nozzles.
EXTERIOR NAME PLATES -
TAPE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.Fig. 6 COWL COVER
1 - COWL COVER
2 - WIPER PIVOT
3 - WASHER HOSES
4 - HOOD
Fig. 7 COWL COVER RETAINERS
1 - SCREW
2 - WINDSHIELD
3 - COWL COVER
4 - FRONT FENDER
23 - 50 EXTERIORRS
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INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.
(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove hood cable.
(6) Remove hood prop rod.
(7) Remove screw attaching coolant recovery bottle
to crossmember.
(8) Remove bolts attaching radiator isolators to
crossmember.
(9) Remove bolts attaching ends of crossmember to
radiator closure panel (Fig. 14).
(10) Lift crossmember upward and away from
radiator closure panel.
(11) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14) . Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
Fig. 14 RADIATOR CLOSURE PANEL
CROSSMEMBER
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
23 - 54 EXTERIORRS
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)
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INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten. Tighten
bolts to 13.5 N´m (120 in. lbs.) torque. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(4) Verify hood operation and alignment.
LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 4).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net
pierced tabs. If alignment is required, flatten or
grind tabs.(5) Verify hood operation and alignment. Adjust as
necessary.
(6) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.
LATCH RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 4).
(5) Remove hood release handle from instrument
panel.
Fig. 2 HOOD
1 - HOOD
2 - HOOD LATCH STRIKER
3 - HOOD HALF OF HOOD HINGE
Fig. 3 HOOD LATCH
1 - HOOD RELEASE CABLE
2 - HOOD LATCH
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
Fig. 4 HOOD
1 - RELEASE CABLE CASE
2 - HOOD LATCH
3 - RELEASE CABLE END
RSHOOD23-61
HOOD (Continued)
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(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 5).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.
(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 5) .
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching striker to inside of
hood.
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts attaching hood latch striker to
hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.Fig. 5 HOOD RELEASE CABLE ROUTING
1 - GROMMET
2 - HOOD RELEASE CABLE
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
23 - 62 HOODRS
LATCH RELEASE CABLE (Continued)
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INSTALLATION
(1) Install the glove box latch striker.
(2) Install the screws holding latch striker to
instrument panel.
(3) Close glove box door.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove six retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.
(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Disconnect the wire connectors from the Pas-
senger Airbag.
(6) Remove the two screws to each right and left
cowl trim covers.
(7) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(8) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(9) Disconnect the antenna lead connector from
behind the glove box.
(10) Remove the four screws to the lower steering
column cover.
(11) Remove the eight screws to the steering col-
umn backing plate.
(12) Unclip the Data Link Connector (DLC) from
the steering column backing plate.
(13) Remove two screws to the left side instrument
panel silencer and remove (Fig. 4).
(14) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Remove the two screws to the hood release
handle.
(16) Remove five screws to steering column back-
ing plate and remove (Refer to 23 - BODY/INSTRU-
MENT PANEL/KNEE BLOCKER - REMOVAL).(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 5).
(19) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(20) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
(21) Remove the four nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 6).
(22) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(23) Loosen the left side roll down bolt (Fig. 7).
(24) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(25) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(26) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(27) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(28) Remove the right end cover by pulling out-
board.
(29) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(30) Loosen the right side roll down bolt.
(31) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(32) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(33) Feed power mirror wire harness inboard
through the A-pillar.
(34) Remove the bolts attaching the instrument
panel frame to the dash panel below windshield
opening.
(35) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
RSINSTRUMENT PANEL23-65
GLOVE BOX LATCH STRIKER (Continued)
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