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Instrument Panel Assembly: Installation

WARNING: This page is about a different car, the 2004 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. 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.
  • WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES.
  • USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
  • THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAGS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
  1. Install the instrument panel.
    NOTE: The guides on the bottom of the instrument panel must engage in the cutouts on the left and right next to the heater housing. (Fig 1 and Fig 2 )
    2. Fig 1: Installing Alignment Cutout - 1
    G03567547Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: Installing Alignment Cutout - 2
    G03567548Courtesy of DAIMLERCHRYSLER CORP.
  2. Route wire harness through the panel.
  3. Install and tighten 12 instrument panel screws. (Figure )
    CAUTION: The position of the steering gear must not be altered.
  4. Raise steering column into position and install the bolts. (Figure )
  5. Tighten steering column bolts to 25 N.m (18 ft. lbs.).
  6. Install ignition transponder onto column lock. (Figure )
    NOTE: The dome on the transponder must engage into the groove on the ignition switch.
  7. Install brake pedal spring. (Figure )
  8. Install vent hose. (Figure )
  9. Install instrument panel top cover and screws. (Figure )
  10. Install right outer and inner air nozzles. (Figure )
  11. Install right side cover and screws.
  12. Wrap protective mat around connectors behind instrument cluster.
  13. Install left outer and inner air nozzles.
  14. Install left side cover and screws.
  15. Install passenger side air nozzle cover and bracket and install the screws. (Figure )
  16. Position Power Distribution Center (PDC) in vehicle and connect electrical connectors. (Figure )
  17. Install PDC and install bolt and nut. (Figure )
  18. Install PDC ground cable and nut.
  19. Install steering column shroud and install the two screws and one nut. (Figure )
  20. Install PDC cover and twist lock 1/4 turn to secure in place. (Figure )
  21. Connect electrical connectors and cables to air conditioning push-button module and install. (Figure )
  22. Install center bezel. (Refer to INSTALLATION  .)
  23. Install left and right speakers. (Refer to INSTALLATION .)
  24. Install passenger airbag. (Refer to INSTALLATION .)
  25. Install instrument cluster. (Refer to INSTALLATION .)
  26. Install cup holder. (Refer to INSTALLATION  )
  27. Install glove compartment. (Refer to INSTALLATION  .)
  28. Install radio. (Refer to INSTALLATION .)
  29. Connect battery negative cable.
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