perform service JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
Refer to the Fuel Pressure Leak Down Test for more
information.
The electric fuel pump is not a separate, service-
able component.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure.
(2) Disconnect fuel supply line at fuel rail. Refer to
Quick-Connect Fittings. Some engines may require
air cleaner housing removal before line disconnection.
(3) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16º fuel
lines and tool number 6631 is used for 3/8º fuel lines.
(4) Connect correct Fuel Line Pressure Test
Adapter Tool Hose into disconnected fuel supply line.
Insert other end of Adaptor Tool Hose into a gradu-
ated container.
(5) Remove fuel fill cap.(6) To activate fuel pump and pressurize system,
obtain DRBtscan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump will deliver at least 1/10 liter
of fuel in 7 seconds. Do not operate fuel pump for
longer than 7 seconds with fuel line disconnected as
fuel pump module reservoir may run empty.
(a) If capacity is lower than specification, but
fuel pump can be heard operating through fuel fill
cap opening, check for a kinked/damaged fuel sup-
ply line somewhere between fuel rail and fuel
pump module.
(b) If line is not kinked/damaged, and fuel pres-
sure is OK, but capacity is low, replace fuel filter.
Refer to Fuel Filter Removal/Installation for addi-
tional information.
(c) If both fuel pressure and capacity are low,
replace bottom section of fuel pump module. Refer
to Fuel Pump Module Removal/Installation.
DIAGNOSIS AND TESTING - FUEL PUMP
PRESSURE TEST
Use this test in conjunction with the Fuel Pump
Capacity Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found elsewhere in this
group.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
When the electric fuel pump is activated, fuel pres-
sure shouldimmediately(1±2 seconds) rise to spec-
ification.
The fuel system is equipped with a separate fuel
pump module mounted, fuel pressure regulator. The
fuel filter is remotely mounted. The fuel pressure
regulator is not controlled by engine vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
KJFUEL DELIVERY 14 - 15

(1) Remove protective cap at fuel rail test port.
Connect the 0±414 kPa (0-60 psi) fuel pressure gauge
(from gauge set 5069) to test port pressure fitting on
fuel rail (Fig. 20).The DRBtIII Scan Tool along
with the PEP module, the 500 psi pressure
transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engine and note pressure
gauge reading. Fuel pressure should be 339 kPa   34
kPa (49.2 psi   5 psi) at idle.
(3) If engine runs, but pressure is below 44.2 psi,
check for a kinked fuel supply line somewhere
between fuel rail and fuel pump module. If line is not
kinked, but specifications for either the Fuel Pump
Capacity, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, replace lower section
of fuel pump module. Refer to Fuel Pump Module
Removal/Installation.
(4) If operating pressure is above 54.2 psi, electric
fuel pump is OK, but fuel pressure regulator is defec-
tive. Replace lower section of fuel pump module.
Refer to Fuel Pump Module Removal/Installation.
(5) Install protective cap to fuel rail test port.
DIAGNOSIS AND TESTING - FUEL PUMP
AMPERAGE TEST
This amperage (current draw) test is to be done in
conjunction with the Fuel Pump Pressure Test, Fuel
Pump Capacity Test and Fuel Pressure Leak Down
Test. Before performing the amperage test, be sure
the temperature of the fuel tank is above 50É F (10É
C).The DRBtScan Tool along with the DRB Low Cur-
rent Shunt (LCS) adapter (Fig. 21) and its test leads
will be used to check fuel pump amperage specifica-
tions.
(1) Be sure fuel tank contains fuel before starting
test. If tank is empty or near empty, amperage read-
ings will be incorrect.
(2) Obtain LCS adapter.
(3) Plug cable from LCS adapter into DRB scan
tool at SET 1 receptacle.
(4) Plug DRB into vehicle 16±way connector (data
link connector).
(5) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use10 amp (10A +)receptacle
and common (-) receptacles.
(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(11) Press ENTER to change 2 amp scale to 10
amp scale.This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Distribution Center
(PDC).
(13) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
Fig. 20 FUEL PRESSURE TEST GAUGE (TYPICAL
GAUGE INSTALLATION AT TEST PORT)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
Fig. 21 LOW CURRENT SHUNT
1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES
14 - 16 FUEL DELIVERYKJ
FUEL PUMP (Continued)

LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
STANDARD PROCEDURE - STEERING
LINKAGE............................16TIE ROD END
REMOVAL.............................16
INSTALLATION.........................16
LINKAGE
STANDARD PROCEDURE - STEERING LINKAGE
The tie rod end and ball stud seals should be
inspected during all oil changes. If a seal is damaged,
replace the tie rod.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
TIE ROD END
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
NOTE: Mark the tie rod end jam nuts on the steer-
ing gear for easier installation.
(3) Loosen the tie rod end jam nut (Fig. 1).
(4) Remove the tie rod end nut (Fig. 1).
(5) Seperate the tie rod end from the knuckle
using tool C3894A.
NOTE: Count the number of turns when removing.
(6) Remove the tie rod end from the rack (Fig. 1).
INSTALLATION
(1) Install the tie rod end to the rack to the exact
number of turns that it was removed (Fig. 1).(2) Install the tie rod end to the knuckle. Tighten
the nut to 108 N´m (80 ft.lbs).
(3) Tighten the jam nut to 76 N´m (55 ft.lbs). (Fig.
1).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 1 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
19 - 16 LINKAGEKJ

METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Drive vehicle a short distance to eliminate tire
flat spotting from a parked position.
(2) Check wheel bearings and adjust if adjustable
or replace if necessary.
(3) Check the wheel mounting surface.
(4) Relocate wheel on the mounting, two studs
over from the original position.
(5) Tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
(6) Check radial runout. If still excessive, mark
tire sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove tire from wheel and mount wheel on
service dynamic balance machine.
(2) Check wheel radial runout (Fig. 2) and lateral
runout (Fig. 3).
²STEEL WHEELS: Radial runout 0.024 in., Lat-
eral runout 0.030 in. (average)
²ALUMINUM WHEELS: Radial runout 0.014 in.,
Lateral runout 0.020 in. (average)
(3) If point of greatest wheel lateral runout is near
original chalk mark, remount tire 180 degrees.
Recheck runout, (Refer to 22 - TIRES/WHEELS -
STANDARD PROCEDURE).
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION
Tires on the front and rear operate at different
loads and perform different steering, driving, and
braking functions. For these reasons they wear at
unequal rates and tend to develop irregular wear
patterns. These effects can be reduced by rotating
the tires at regular intervals. The benefits of tire
rotation are:
²Increase tread life
²Maintain traction levels
²A smooth, quiet ride
The suggested method of tire rotation is (Fig. 4).
Other rotation methods can be used, but they will
not provide all the tire longevity benefits.
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 4 Tire Rotation Pattern
22 - 2 TIRES/WHEELSKJ
TIRES/WHEELS (Continued)

INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL............................147
INSTALLATION........................147
GLOVE BOX
REMOVAL............................148
INSTALLATION........................148
GLOVE BOX LATCH
REMOVAL............................148
INSTALLATION........................148
GLOVE BOX LATCH STRIKER
REMOVAL............................148
INSTALLATION........................149
INSTRUMENT PANEL ASSEMBLY
REMOVAL............................149
INSTALLATION........................151
INSTRUMENT PANEL TOP COVER
REMOVAL............................152INSTALLATION........................153
INSTRUMENT PANEL END CAP
REMOVAL............................153
INSTALLATION........................153
INSTRUMENT PANEL DRIVER SIDE BEZELS
REMOVAL............................153
INSTALLATION........................154
INSTRUMENT PANEL CENTER BEZEL
REMOVAL............................154
INSTALLATION........................154
INSTRUMENT PANEL PASSENGER SIDE
BEZEL
REMOVAL............................154
INSTALLATION........................154
KNEE BLOCKER
REMOVAL............................155
INSTALLATION........................155
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 drives side trim bezels. (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL DRIVER SIDE BEZEL - REMOVAL)
(2) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the seven screws and remove the clus-
ter 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) Install the cluster bezel and the seven screws.
(2) Install the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
(3) Install the drives side trim bezels. (Refer to 23
- BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL DRIVER SIDE BEZEL - INSTALLATION)
KJINSTRUMENT PANEL 23 - 147

GLOVE BOX
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 the glove box.
(2) Squeeze the stop tabs located on the sides of
the box and allow the box to open fully.
(3) With box in the full down position slide the box
to the right off of the hinges and remove.
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 box on and slide the box to the left
to engage the hinges.
(2) Close the glove box.
GLOVE BOX LATCH
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 BATTERYNEGATIVE (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 glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(2) Remove the nine screws and remove the glove
box skin.
(3) Remove the latch from the locators.
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 latch onto the locators.
(2) Install the glove box skin onto the glove box
and install the nine screws.
(3) Install the glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION)
GLOVE BOX LATCH STRIKER
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.
23 - 148 INSTRUMENT PANELKJ

(1) Open the glove box.
(2) Remove the two striker screws and remove the
latch striker.
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) Install the striker and install the two screws.
(2) Loosen the screws to adjust if necessary.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the speakers.
(4) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(5) Remove the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL)
(6) Remove the four nuts and remove the center
support bracket. (Fig. 6)
(7) Remove the steering column. (Refer to 19 -
STEERING/COLUMN - REMOVAL)
(8) Remove the drivers side cowl trim cover. (Refer
to 23 - BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(9) Disconnect the wire harness connector behind
the drivers side cowl trim cover.
(10) Disconnect the green and light blue wire har-
ness bulk connectors at the junction block. (Fig. 1)
(11) Disconnect the electrical connector at the
inner side of the pedal support bracket. (Fig. 2)
(12) Remove the two bolts at the front of the pedal
support bracket. (Fig. 2)
(13) Remove the two bolts from the bottom side of
the pedal support bracket. (Fig. 2)
Fig. 1 JUNCTION BLOCK CONNECTORS
1 - ELECTRICAL CONNECTOR
2 - ELECTRICAL CONNECTOR
3 - PEDAL SUPPORT BRACKET
4 - JUNCTION BLOCK
KJINSTRUMENT PANEL 23 - 149
GLOVE BOX LATCH STRIKER (Continued)

(8) Install the two roll down bracket bolts at the
right cowl side panel and tighten to 54 N´m (40 ft.
lbs.).
(9) Install the HVAC mounting bolt at the lower
outside corner of the glove box opening and tighten
to 6 N´m (55 in. lbs.).
(10) Install the HVAC mounting bolt above the
glove box striker.
(11) Install the passenger side trim bezel. (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL PASSENGER SIDE BEZEL - INSTALLA-
TION)
(12) Install the passenger side cowl trim cover.
(Refer to 23 - BODY/INTERIOR/COWL TRIM
COVER - INSTALLATION)
(13) Install the glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION)
NOTE: Do not push or pull bracket. Tighten at the
rest position.
(14) Install the two roll down bracket bolts at the
drivers cowl side panel and tighten to 54 N´m (40 ft.
lbs.).
(15) Install the two bolts at the bottom side of the
pedal support bracket.
(16) Install the two bolts at the front of the pedal
support bracket.
(17) Connect the electrical connector at the inner
side of the pedal support bracket.
(18) Connect the wiring harness electrical connec-
tors at the junction block.
(19) Connect the wire harness electrical connector
behind the drivers side cowl trim cover.
(20) Install the left cowl trim cover. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER - INSTAL-
LATION)
(21) Install the steering column. (Refer to 19 -
STEERING/COLUMN - INSTALLATION)
(22) Install the two HVAC mounting bolts behind
the center trim.
(23) Install the ground strap and bolt and connect
the restraint module electrical connector.
(24) Install the center support bracket and hold it
tight against the instrument panel.
(25) Tighten the lower nuts to 23 N´m (17 ft. lbs.).
(26) Tighten the upper bracket nuts to 23 N´m (17
ft. lbs.).
(27) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(28) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(29) Install the speakers.
(30) Install the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)(31) Reconnect the battery ground cable.
INSTRUMENT PANEL TOP
COVER
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 a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM AND GRAB HANDLE -
REMOVAL)
(2) Using a trim stick C-4755 or equivalent,
release the attachment clips and remove the top
cover. (Fig. 7)
Fig. 7 INSTRUMENT PANEL COVERS
1 - SIDE COVER
2 - INSTRUMENT PANEL ASSEMBLY
3 - TOP COVER
23 - 152 INSTRUMENT PANELKJ
INSTRUMENT PANEL ASSEMBLY (Continued)

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 top cover and seat the clips fully.
(2) Install the a-pillar trim panels. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM AND GRAB
HANDLE - INSTALLATION)
INSTRUMENT PANEL END CAP
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 the door.
(2) Using the finger indent, grasp and remove the
side cover. (Fig. 7)
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 FURTHERDIAGNOSIS 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 side panels and seat the clips fully.
INSTRUMENT PANEL DRIVER
SIDE BEZELS
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) Using a trim stick C-4755 or equivalent, disen-
gage the bezels on either side of the steering column.
(Fig. 8)
Fig. 8 INSTRUMENT PANEL TRIM BEZELS
1 - INSTRUMENT PANEL
2 - DRIVERS SIDE TRIM BEZELS
3 - CENTER TRIM BEZEL
4 - SCREW
5 - PASSENGER SIDE TRIM BEZEL
KJINSTRUMENT PANEL 23 - 153
INSTRUMENT PANEL TOP COVER (Continued)

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 appropriate divers side bezels on
either side of the steering column and seat the
attachment clips.
INSTRUMENT PANEL CENTER
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 ashtray and remove the screw.
(2) Using a trim stick C-4755 or equivalent,
remove the center bezel from the instrument panel
assembly. (Fig. 8)
(3) Disconnect the electrical and vacuum connec-
tors.
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) Connect the electrical and vacuum connectors.
(2) Position the center bezel and seat the retaining
clips starting with the lower clips first.
(3) Install the screw and install the ash tray.
INSTRUMENT PANEL
PASSENGER SIDE 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 two screws.
(2) Using a trim stick C-4755 or equivalent,
release the retaining clips and remove the passenger
side bezel. (Fig. 8)
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.
23 - 154 INSTRUMENT PANELKJ
INSTRUMENT PANEL DRIVER SIDE BEZELS (Continued)