Headlamp installation DODGE RAM 1500 1998 2.G User Guide

(2) From the underside of the cowl plenum cover/
grille panel, reconnect the cowl plenum and washer
nozzle hoses to the three barbed nipples of the check
valve.
(3) Reinstall the cowl plenum cover/grille panel
over the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(4) Close and latch the hood.
(5) Reinstall both wiper arms onto the wiper piv-
ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fluid level switch is a single pole, sin-
gle throw reed-type switch mounted on the outboard
side of the of the washer reservoir in the engine com-
partment (Fig. 6). Only the molded plastic switch
mounting flange and the integral connector recepta-
cle are visible when the switch is installed in the res-
ervoir. A short nipple formation extends from the
inner surface of the switch mounting flange, and a
barb on the nipple near the switch mounting flange
is pressed through a rubber grommet seal installed
in the mounting hole of the reservoir.
A small, molded plastic float has two pivot pins
near its center that are snapped into two receptacles
near the ends of two stanchions that extend toward
the float from the switch nipple formation. A small
magnet is secured within the end of the float nearestthe switch nipple formation, and a reed switch is con-
cealed within the nipple. A diagnostic resistor is con-
nected between the two switch terminals within the
switch mounting flange. The washer fluid level
switch cannot be adjusted or repaired. If faulty or
damaged, the switch must be replaced.
OPERATION
The washer fluid level switch uses a pivoting,
oblong float to monitor the level of the washer fluid
in the washer reservoir. The float contains a small
magnet. When the float pivots, the proximity of this
magnet to a stationary reed switch within the nipple
formation of the switch changes. When the fluid level
in the washer reservoir is at or above the float level,
the float moves to a vertical position, the influence of
the float magnetic field is removed from the reed
switch, and the normally open reed switch contacts
open. When the fluid level in the washer reservoir
falls below the level of the pivoting float, the float
moves to a horizontal position, the influence of the
float magnetic field is applied to the reed switch, and
the contacts of the normally open reed switch close.
The washer fluid level switch is connected to the
vehicle electrical system through a dedicated take
out and connector of the right (except diesel engines)
or left (diesel engines only) headlamp and dash wire
harness. The switch is connected in series between a
clean ground output of the Front Control Module
Fig. 5 Check Valve Remove/Install
1 - WASHER NOZZLE HOSE (RIGHT)
2 - CHECK VALVE
3 - ROUTING CLIP
4 - COWL PLENUM WASHER HOSE
5 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE)
6 - WASHER NOZZLE HOSE (LEFT)
Fig. 6 Washer Fluid Level Switch
1 - MOUNTING FLANGE
2 - BARBED NIPPLE
3 - FLOAT
4 - RESERVOIR
5 - GROMMET SEAL
6 - PIVOT
7 - MAGNET
8 - CONNECTOR RECEPTACLE
DRWIPERS/WASHERS 8R - 9
CHECK VALVE (Continued)

INSTALLATION
(1) Install a new rubber grommet seal into the
washer fluid level switch mounting hole in the
washer reservoir. Always use a new rubber grommet
seal on the reservoir.
(2) Insert the float of the washer fluid level switch
through the rubber grommet seal and into the
washer reservoir. The connector receptacle of the
washer fluid level switch should be pointed upward.
(3) Using hand pressure, press firmly and evenly
on the washer fluid level switch mounting flange
until the barbed nipple is fully seated in the rubber
grommet seal in the washer reservoir mounting hole.
(4) Reconnect the right (except diesel engine) or
left (diesel engine only) headlamp and dash wire har-
ness connector for the washer fluid level switch to
the switch connector receptacle (Fig. 7) or (Fig. 8).
(5) Reconnect the removed washer hose to the
barbed outlet nipple of the washer pump/motor unit.
(6) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(7) Reconnect the battery negative cable.
(8) Close and latch the hood.
WASHER HOSES/TUBES
DESCRIPTION
The washer plumbing consists of a small diameter
rubber reservoir washer hose that is routed from the
barbed outlet nipple of the electric washer pump/mo-tor unit on the washer reservoir through a trough
molded into the back of the reservoir above the
washer pump and to the engine compartment washer
hose (Fig. 9). On models equipped with an optional
diesel engine, the reservoir washer hose is routed
through routing clips on the top of the radiator fan
shroud from the washer reservoir on the left side of
the radiator to the engine compartment washer hose
on the right side of the radiator. The engine compart-
ment washer hose is contained within the right head-
lamp and dash wire harness, which is routed through
the engine compartment along the top of the right
front fender wheel house to the dash panel.
The engine compartment washer hose is connected
to the washer reservoir washer hose and to the cowl
plenum washer hose with molded plastic in-line fit-
tings that have a barbed nipple on each end. The
cowl plenum washer hose is routed from the engine
compartment into the cowl plenum area through a
trough formation located near the right end of the
cowl plenum cover/grille panel. The cowl plenum
washer hose is connected to the washer system check
valve/wye fitting on the underside of the cowl plenum
cover/grille panel. The cowl plenum washer hose and
the two washer nozzle hoses are routed through inte-
gral routing clips on the underside of the cowl ple-
num cover/grille panel. The cowl plenum washer hose
is connected to one nipple on the wye fitting and the
two washer nozzle hoses are connected to the other
two wye fitting nipples. The washer nozzle hoses are
then routed along the underside of the cowl plenum
cover/grille panel to the two washer nozzles.
Washer hose is available for service only as roll
stock, which must then be cut to length. The molded
plastic washer hose fittings cannot be repaired. If
these fittings are faulty or damaged, they must be
replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized
and fed by the washer pump/motor through the
washer system plumbing and fittings to the two
washer nozzles. Whenever routing the washer hose
or a wire harness containing a washer hose, it must
be routed away from hot, sharp, or moving parts;
and, sharp bends that might pinch the hose must be
avoided.
WASHER NOZZLE
DESCRIPTION
The two washer nozzles have integral snap fea-
tures and an anti-rotation tab that secure them in
dedicated holes in the cowl plenum cover/grille panel
located near the base of the windshield (Fig. 10). The
Fig. 9 Engine Compartment Washer Hose
1 - RIGHT FENDER
2 - RIGHT HEADLAMP & DASH WIRE HARNESS
3 - ENGINE COMPARTMENT WASHER HOSE (TO COWL
PLENUM)
4 - COWL PLENUM WASHER HOSE
5 - ENGINE COMPARTMENT WASHER HOSE (TO WASHER
RESERVOIR)
DRWIPERS/WASHERS 8R - 11
WASHER FLUID LEVEL SWITCH (Continued)

(7) Reinstall both wiper arms onto the wiper piv-
ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).
WASHER PUMP/MOTOR
DESCRIPTION
The washer pump/motor unit (Fig. 12) is located on
the rearward facing surface of the washer reservoir,
in the right (except diesel engine) or left (diesel
engine only) front corner of the engine compartment.
A small permanently lubricated and sealed electric
motor is coupled to the rotor-type washer pump. A
seal flange with a barbed inlet nipple on the pump
housing passes through a rubber grommet seal
installed in a dedicated mounting hole of the washer
reservoir. When the pump is installed in the reser-
voir a barbed outlet nipple on the pump housing con-
nects the unit to the washer system through a short
washer reservoir hose.
The washer pump/motor unit is retained on the
reservoir by the interference fit between the barbed
pump inlet nipple and the grommet seal, which is a
light press fit. The top of the washer pump is also
secured to the washer reservoir by the use of a snappost on the motor housing and a snap post receptacle
molded into the reservoir that allows for mounting of
the washer pump without the use of fasteners. An
integral connector receptacle on the top of the motor
housing connects the unit to the vehicle electrical
system. The washer pump/motor unit cannot be
repaired. If faulty or damaged, the entire washer
pump/motor unit must be replaced.
OPERATION
The washer pump/motor unit features a small
Direct Current (DC) electric motor. The motor is con-
nected to the vehicle electrical system through a sin-
gle take out and two-cavity connector of the right
(except diesel engine) or left (diesel engine only)
headlamp and dash wire harness. The motor is
grounded at all times through another take out of
the right (except diesel engine) or left (diesel engine
only) headlamp and dash wire harness. On models
without the diesel engine, a single eyelet terminal
connector is secured by a nut to a ground stud
located on the right front fender inner shield in the
engine compartment. On models with a diesel engine,
an eyelet terminal connector is secured by a ground
screw to the left front fender inner shield in the
engine compartment. The motor receives battery cur-
rent on a washer pump/motor control circuit.
The washer pump/motor control circuit is energized
through a high side driver within the Front Control
Module (FCM) whenever the FCM receives an elec-
tronic message requesting washer system operation
from the instrument cluster over the Programmable
Communications Interface (PCI) data bus. The
instrument cluster monitors a resistor multiplexed
hard wired input from the momentary washer switch
contacts within the multi-function switch on the
steering column to determine when it should issue
the electronic message requesting washer system
operation.
Washer fluid is gravity-fed from the washer reser-
voir to the inlet side of the washer pump. When the
pump motor is energized, the motor spins the rotor
within the washer pump. The spinning pump rotor
pressurizes the washer fluid and forces it through
the pump outlet nipple, the washer plumbing, and
the washer nozzles onto the windshield glass.
The washer pump/motor unit may be diagnosed
using conventional diagnostic tools and methods.
However, conventional diagnostic methods may not
prove conclusive in the diagnosis of the instrument
cluster, the FCM, or the electronic message inputs to
or outputs from the instrument cluster and the FCM
that control the operation of the washer pump/motor
unit. The most reliable, efficient, and accurate means
to diagnose the washer pump/motor unit, the instru-
ment cluster, the FCM, or the electronic message
Fig. 12 Washer Pump/Motor
1 - MOTOR
2 - SNAP POST
3 - CONNECTOR RECEPTACLE
4 - PUMP
5 - OUTLET NIPPLE
6 - INLET NIPPLE
7 - FILTER SCREEN
DRWIPERS/WASHERS 8R - 13
WASHER NOZZLE (Continued)

inputs and outputs related to the washer pump/mo-
tor unit operation requires the use of a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
REMOVAL
The washer pump/motor unit can be removed from
the washer reservoir without removing the reservoir
from the vehicle.
(1) Unlatch and open the hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the washer hose from the barbed
outlet nipple of the washer pump/motor unit and
allow the washer fluid to drain into a clean container
for reuse.
(4) Disconnect the right (except diesel engine) or
left (diesel engine only) headlamp and dash wire har-
ness connector for the washer pump/motor unit from
the motor connector receptacle (Fig. 13).
(5) Firmly grasp the top of the washer pump/motor
housing.
(6) Pull lightly outward on the top of the washer
pump/motor housing away from the washer reservoir
far enough to disengage the snap post on the top of
the motor from the receptacle in the reservoir.(7) Pull the washer pump/motor unit straight out
from the washer reservoir far enough to disengage
the barbed pump inlet nipple from the rubber grom-
met seal in the reservoir.
(8) Disconnect the reservoir washer hose from the
washer pump/motor unit outlet nipple.
(9) Remove washer pump/motor unit from the back
of the washer reservoir.
(10) Remove the rubber grommet seal from the
washer reservoir and discard.
INSTALLATION
(1) Install a new rubber grommet seal into the
washer pump mounting hole in the washer reservoir.
Always use a new rubber grommet seal on the reser-
voir.
(2) Position the barbed inlet nipple of the washer
pump to the rubber grommet seal in the washer res-
ervoir (Fig. 13).
(3) Using hand pressure, press on the washer
pump/motor unit firmly and evenly until the barbed
inlet nipple is fully seated in the rubber grommet
seal in the washer reservoir mounting hole.
(4) Align the washer pump/motor snap post on the
top of the motor housing with the snap post recepta-
cle in the washer reservoir.
(5) Using hand pressure, press firmly and evenly
on the top of washer pump/motor unit until the snap
post snaps into the washer reservoir receptacle.
(6) Reconnect the washer reservoir hose to the
barbed outlet nipple of the washer pump.
(7) Reconnect the right (except diesel engine) or
left (diesel engine only) headlamp and dash wire har-
ness connector for the washer pump/motor unit to
the motor connector receptacle.
(8) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(9) Reconnect the battery negative cable.
(10) Close and latch the hood.
WASHER RESERVOIR
DESCRIPTION
Except on models equipped with an optional diesel
engine, the molded plastic washer fluid reservoir is
mounted on the right rearward facing surface of the
cooling module radiator shroud in the engine com-
partment (Fig. 14). On models with the diesel engine,
the molded plastic washer fluid reservoir is mounted
on the rearward facing surface of the left vertical
member of the radiator support in the engine com-
partment. The reservoir is a molded unit constructed
of a translucent plastic that allows the washer fluid
level to be inspected without removing the washer
Fig. 13 Washer Pump/Motor Remove/Install
1 - CONNECTOR RECEPTACLE
2 - SNAP POST
3 - SNAP POST RECEPTACLE
4 - GROMMET SEAL
5 - WASHER FLUID LEVEL SWITCH
6 - WASHER RESERVOIR
7 - INLET NIPPLE
8 - OUTLET NIPPLE
8R - 14 WIPERS/WASHERSDR
WASHER PUMP/MOTOR (Continued)

INSTALLATION
INSTALLATION - EXCEPT DIESEL ENGINE
(1) Position the washer reservoir into the right
side of the engine compartment.
(2) Align and insert the three mounting tabs (one
at the top and two at the bottom) into the two slots
at the bottom and the channel-like slot at the top of
the radiator shroud (Fig. 15).
(3) Place both hands on the top of the washer res-
ervoir and push the unit downward far enough for
the locking feature on the washer reservoir to snap
into the depression in the radiator shroud.
(4) Reconnect the right headlamp and dash wire
harness connector for the washer pump/motor unit to
the motor connector receptacle.
(5) Reconnect the right headlamp and dash wire
harness connector for the washer fluid level switch to
the switch connector receptacle.
(6) Reconnect the reservoir washer hose to the
barbed nipple of the inline fitting at the engine com-
partment washer hose in the right headlamp and
dash wire harness.
(7) Reposition the coolant recovery container or the
coolant pressure container to the top of the cooling
module and reinstall the fasteners that secure it
there. (Refer to 7 - COOLING/ENGINE/COOLANT
RECOVERY CONTAINER - INSTALLATION) or
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESSURE CONTAINER - INSTALLATION).
(8) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(9) Reconnect the battery negative cable.
(10) Close and latch the hood.
INSTALLATION - DIESEL ENGINE
(1) Position the washer reservoir into the left side
of the engine compartment (Fig. 17).
(2) Install and tighten the two screws that secure
the washer reservoir to the left vertical member of
the radiator support. Tighten the screws to 10 N´m
(85 in. lbs.).
(3) Reconnect the left headlamp and dash wire
harness connector for the washer pump/motor unit to
the motor connector receptacle (Fig. 16).
(4) Reconnect the left headlamp and dash wire
harness connector for the washer fluid level switch to
the switch connector receptacle.
(5) Reconnect the reservoir washer hose to the
barbed nipple of the inline fitting at the engine com-
partment washer hose in the right headlamp and
dash wire harness.
(6) Engage the reservoir washer hose into the inte-
gral routing clips on the top of the radiator fan
shroud.
(7) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(8) Reconnect the battery negative cable.
(9) Close and latch the hood.
WIPER ARM
DESCRIPTION
The wiper arms are the rigid members located
between the wiper pivots that protrude from the cowl
Fig. 17 Washer Reservoir
Remove/Install - Diesel Engine
1 - RESERVOIR WASHER HOSE
2 - RADIATOR SUPPORT
3 - SCREW (2)
4 - WASHER RESERVOIR
Fig. 18 Wiper Arm
1 - HOOK
2 - STRAP
3 - PIVOT END
4 - KEY
5-LATCH
6 - HINGE PIN
7 - TENSION SPRING
8 - CHANNEL
DRWIPERS/WASHERS 8R - 17
WASHER RESERVOIR (Continued)

OPERATION
The wiper module operation is controlled by the
battery current inputs received by the wiper motor
through the wiper on/off and wiper high/low relays.
The wiper motor speed is controlled by current flow
to either the low speed or the high speed set of
brushes. The park switch is a single pole, single
throw, momentary switch within the wiper motor
that is mechanically actuated by the wiper motor
transmission components. The park switch alter-
nately opens and closes the wiper park switch sense
circuit to ground, depending upon the position of the
wipers on the glass. This feature allows the motor to
complete its current wipe cycle after the wiper sys-
tem has been turned Off, and to park the wiper
blades in the lowest portion of the wipe pattern. The
automatic resetting circuit breaker protects the
motor from overloads. The wiper motor crank arm,
the two wiper linkage members, and the two wiper
pivots mechanically convert the rotary output of the
wiper motor to the back and forth wiping motion of
the wiper arms and blades on the glass.
REMOVAL
(1) Remove both wiper arms from the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - REMOVAL).
(2) Unlatch and open the hood.
(3) Disconnect and isolate the battery negative
cable.
(4) Remove the cowl plenum cover/grille panel
from over the cowl plenum. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the left headlamp and dash wire
harness connector for the wiper motor from the
motor pigtail wire connector (Fig. 26).(6) Remove the two screws that secure the wiper
module to the top of the cowl plenum panel at the
pivot brackets.
(7) Remove the two screws that secure the wiper
module to the bottom of the cowl plenum panel.
(8) Remove the wiper module from the cowl ple-
num panel as a unit.
INSTALLATION
(1) Position the wiper module into the cowl ple-
num as a unit (Fig. 26).
(2) Install the two screws that secure the wiper
module to the top of the cowl plenum panel at the
pivot brackets. Tighten the screw on the driver side,
followed by the screw on the passenger side. Tighten
the screws to 7 N´m (60 in. lbs.).
(3) Install and tighten the screws that secure the
wiper module to the bottom of the cowl plenum
panel. Tighten the screw on the passenger side, fol-
lowed by the screw on the driver side. Tighten the
screws to 7 N´m (60 in. lbs.).
(4) Reconnect the left headlamp and dash wire
harness connector for the wiper motor to the motor
pigtail wire connector.
(5) Reinstall the cowl plenum cover/grille panel
over the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(6) Reconnect the battery negative cable.
(7) Close and latch the hood.
(8) Reinstall both wiper arms onto the wiper piv-
ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARMS - INSTALLATION).
DRWIPERS/WASHERS 8R - 23
WIPER MODULE (Continued)

(14) Remove the bolts attaching the lower radiator
crossmember to the hydroform fender rail. (Fig. 18)
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(15) Using a reciprocating saw or equivalent, cut
the fender rail and shotgun at a straight and square
section of the hydroform and remove.
(16) Smooth and square the cut edges.
(17) Using the damaged structure as a reference
cut the service part at the same location as the first
cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the
remaining structure and provide the same overall
vehicle geometry.
(18) Fabricate 51 mm (2.0 in.) long repair inserts
using scrap from the old structure or the replacement
part. It will be necessary to split the inserts on each
of their four sides to fit into the hydroform.
(19) Remove any paint or e-coat from the inserts
and also to the interior and exterior of the hydro-
forms.
(20) Cut plug weld holes as described below.
²On the upper rail, cut one 13 mm (0.5 in.) hole
on each side of the rail, 25 mm (1.0 in.) from the butt
joint of the tubes.
²On the lower rail, cut one 13 mm (0.5 in.) hole
on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
²On the lower rail, cut two 13 mm (0.5 in.) holes
on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(21) Install the insert 1º into the replacement part
and tack into place with a weld. (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(22) Insert the service part into place and using
the appropriate measuring equipment, verify the
front end sheet metal bracket's location in all three
(X,Y, and Z) planes of space. (Fig. 19)
(23) Complete all 360É plug welds.
NOTE: Before the final welding, use three dimen-
sional measuring equipment to ensure the part is in
the correct location. Verify that tap plate extrusion
at the bottom of the vertical post lines up with theisolator and hole in the frame perch mount. Also
ensure the lower radiator closure tube is bolted into
the forward shotgun ends.
(24) Complete welding by making a 360É butt weld
around the fender rails.
(25) Metal finish the exposed welds on the hydro-
forms.
(26) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound to the inside of the hydro-
forms ensuring 100% coverage including the mat-
ing face between the fender rail sections and insert
such that corrosion protection is restored in the
internal cavity.
(b) Apply a durable top coat to the outside of the
repair area.
(27) Install the front cab mount bolt if previously
removed and tighten to 81 N´m (60 ft. lbs.).
(28) Install the lower radiator crossmember bolts
and tighten to 28 N´m (21 ft. lbs.).
(29) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(30) Install the upper radiator crossmember. (Refer
to 23 - BODY/EXTERIOR/UPPER RADIATOR
CROSSMEMBER - INSTALLATION)
(31) Install the wire harness and ground if previ-
ously removed and install the bolts.
(32) Install the integrated power module, if previ-
ously removed. (Refer to 8 - ELECTRICAL/POWER
DISTRIBUTION/INTEGRATED POWER MODULE -
INSTALLATION)
(33) Install the air cleaner bracket and air cleaner,
if previously removed. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION)
(34) Install the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
(35) Install the A/C lines, if previously removed.
Refer to the Heating and Air Conditioning section of
the manual for the recommended procedures.
(36) Install the A/C condenser, if previously
removed. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C CONDENSER - INSTAL-
LATION)
(37) Install the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - INSTALLATION)
(38) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
(39) Reconnect the battery ground.
13 - 12 FRAMES & BUMPERSDR
FRAME (Continued)

FRONT FENDER
REMOVAL
(1) Remove the antenna, if equipped. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
REMOVAL)
(2) Remove the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
REMOVAL)
(3) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(4) Remove the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(5) Remove the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(6) Remove the inside and lower bolts. (Fig. 6)
(7) Remove the two bolts below the headlamp.
(8) Remove the hinge support bolt at the cowl.
(9) Remove the three bolts along the fender rail.
INSTALLATION
(1) Install the three bolts along the upper fender
rail and tighten to 9 N´m (80 in. lbs.).
(2) Install the upper hinge support bolt at the cowl
and tighten to 17 N´m (13 ft. lbs.).
(3) Install the two bolts below the headlamp and
tighten to 9 N´m (80 in. lbs.).(4) Install the inside and lower bolts and tighten
to 17 N´m (13 ft. lbs.).
(5) Check the fender positioning and adjust as
required by adding shims. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(6) Install the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
(7) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION)
(10) Install the antenna, if required. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
INSTALLATION)
FUEL FILL DOOR
REMOVAL
(1) Open fill door and remove the bolts. (Fig. 7)
(2) Remove the door.
INSTALLATION
(1) Install the fuel fill door.
(2) Install the bolts and tighten to 9 N´m (80 in.
lbs.).
Fig. 6 FRONT FENDER
1 - HOOD HINGE SUPPORT BOLT (1)
2 - HOOD HINGE
3 - INNER BOLT (1)
4 - FRONT BOLTS (2)
5 - LOWER BOLT INSERT
6 - FENDER
7 - UPPER BOLTS (3)
Fig. 7 FUEL FILL DOOR
1 - FUEL FILL DOOR
2 - BOLTS (2)
DREXTERIOR 23 - 39

INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL.............................49
INSTALLATION.........................49
ASH RECEIVER
REMOVAL.............................50
INSTALLATION.........................51
CUP HOLDER
REMOVAL.............................51
INSTALLATION.........................51
GLOVE BOX
REMOVAL.............................52
INSTALLATION.........................52
GLOVE BOX LATCH
REMOVAL.............................52
INSTALLATION.........................52
INSTRUMENT PANEL ASSEMBLY
REMOVAL.............................52
INSTALLATION.........................55
INSTRUMENT PANEL HEADLAMP SWITCH
BEZEL
REMOVAL.............................56
INSTALLATION.........................56INSTRUMENT PANEL CENTER BEZEL
REMOVAL.............................57
INSTALLATION.........................57
INSTRUMENT PANEL DRIVER SIDE BEZEL
REMOVAL.............................58
INSTALLATION.........................58
INSTRUMENT PANEL TOP COVER
REMOVAL.............................58
INSTALLATION.........................59
INSTRUMENT PANEL LOWER SURROUND
REMOVAL.............................59
INSTALLATION.........................59
STEERING COLUMN OPENING COVER
REMOVAL.............................60
INSTALLATION.........................60
STEERING COLUMN OPENING SUPPORT
BRACKET
REMOVAL.............................60
INSTALLATION.........................60
STORAGE BIN
REMOVAL.............................61
INSTALLATION.........................61
CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the headlamp switch bezel. (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SWITCH BEZEL - REMOVAL)
(2) Remove the center bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - REMOVAL)(3) Remove the two top screws. (Fig. 1)
(4) Using a trim stick C-4755 or equivalent, sepa-
rate the two lower clips.
(5) Disengage the two top attachment bosses and
remove the bezel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cluster bezel over the cluster and
seat the outer bosses over the posts on the left and
right sides.
DRINSTRUMENT PANEL 23 - 49

(2) Snap the top edge of the bezel into place fully.
(3) Seat the two bottom clips fully.
(4) Install the two top screws.
(5) Install the center bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - INSTALLATION)
(6) Install the headlamp switch bezel. (Refer to 23
- BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SWITCH BEZEL - INSTALLATION)
ASH RECEIVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.(1) Open ash receiver and place hand inside. (Fig.
2)
(2) Apply force with anabruptdownward motion
and roll rearward. (Fig. 3)
(3) Dislodge and roll ash receiver out of panel to
remove.
Fig. 1 CLUSTER BEZEL
1 - INSTRUMENT PANEL
2 - SCREWS (2)
3 - CLUSTER BEZEL
4 - CLIP FASTENERS (2)
Fig. 2 ASH RECEIVER
1 - ASH RECEIVER
2 - CUP HOLDER
Fig. 3 ASH RECEIVER REMOVAL
1 - LOCKING TABS
2 - CUP HOLDER
3 - ASH RECEIVER
23 - 50 INSTRUMENT PANELDR
CLUSTER BEZEL (Continued)