Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Removal & Installation

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CAUTION
On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, 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.

  1. Turn the ignition switch to the RUN position.
  2.  
  3. Locate the temperature control knob in the mid (12 o'clock) position.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Disconnect and isolate the battery negative cable.
  8.  
  9. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  10.  
  11. Remove the HVAC housing from the vehicle:
    1. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings.
    2.  
    3. Remove the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings.
    4.  
    5. Drain the engine cooling system.
    6.  
    7. Disconnect the heater hoses from the heater core tubes.
    8.  
    9. Remove the Powertrain Control Module (PCM) from the dash panel and set it aside, but do not unplug the PCM wire harness connectors. Refer to Electronic Control Modules for the procedures.
    10.  
    11. Remove the nuts from the HVAC housing mounting studs on the engine compartment side of the dash panel.
    12.  
    13. Remove the nuts that secure the HVAC housing to the mounting studs on the passenger compartment side of the dash panel.
    14.  
    15. Pull the HVAC housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes.
    16.  
    17. Remove the HVAC housing from the vehicle.
    18.  

  12.  
  13. Unplug the wire harness connector from the blend door actuator.
  14.  
  15. Remove the two mounting screws which secure the actuator to the housing.
  16.  
  17. Slide the blend door actuator off the blend door shaft.
    NOTE
    A black plastic coupler may be attached to the blend door shaft. Remove the coupler and inspect for damage. Reinstall if there is no damage found.

  18.  

To install:


NOTE
Before installing the blend door actuator, be certain that the blend door is not binding and is capable of full travel in both directions.

  1. Align the actuator with the blend door shaft and rotate the actuator to align it to the mounting bosses on the HVAC housing.
  2.  
  3. Align and install the actuator screws. Tighten the mounting screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Plug in the wire harness connector to the blend door actuator.
  6.  
  7. Install the HVAC housing in the vehicle, as follows.
    1. Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
    2.  
    3. Install the nuts that secure the HVAC housing to the mounting studs on the passenger compartment side of the dash panel. Tighten the nuts to 40 inch lbs. (4.5 Nm).
    4.  
    5. Install and tighten the nuts onto the HVAC housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 60 inch lbs. (7 Nm).
    6.  
    7. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system.
    8.  
    9. If the vehicle is not equipped with air conditioning, proceed to installation of the instrument panel. If the vehicle is equipped with air conditioning, install the accumulator. Connect the accumulator inlet tube coupler to the evaporator outlet tube.
    10.  

  8.  
  9. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube.
    1. Evacuate and charge the refrigerant system, as outlined in this section.
    2.  
    3. Reinstall the PCM to the dash panel.
    4.  

  10.  
  11. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  12.  
  13. Make sure the Temperature Control Knob is in the mid (12 o'clock) position to allow the actuator to automatically position itself in the mid position and come to a complete stop when powered up.
  14.  
  15. Connect the battery negative cable.
  16.  


CAUTION
On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, 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.


NOTE
The single zone heating and air conditioning system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend air door and one for the passenger side blend air door. The same service procedures can be used for each of these actuators.

  1. Disconnect and isolate the battery negative cable.
  2.  
  3. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  4.  
  5. Disconnect the wire harness connector from the blend door actuator(s).

    Click image to see an enlarged view

    Fig. HVAC housing, dual zone shown (single zone similar)-nut (1), passenger blend door actuator (2), nut (3), inlet baffle (4), recirc door actuator (5), recirc air door (6), driver side blend door actuator (7), HVAC housing (8), bolt (9), defroster door actuator (10), mode door actuator (11)

    HVAC housing, dual zone shown (single zone similar)-nut (1), passenger blend door actuator (2), nut (3), inlet baffle (4), recirc door actuator (5), recirc air door (6), driver side blend door actuator (7), HVAC housing (8), bolt (9), defroster door actuator (10), mode door actuator (11)
  6.  
  7. Remove the screws that secure the blend door actuator(s) to the HVAC housing.
  8.  
  9. Remove the blend door actuator(s) from the HVAC housing.
  10.  

To install:

  1. Position the blend door actuator(s) into the HVAC housing. If necessary, rotate the actuator(s) slightly to align the splines on the actuator output sleeve(s) with those on the blend door linkage.
  2.  
  3. Install and tighten the screws that secure the blend door actuator(s) to the HVAC housing. Tighten the screws to 17 inch lbs. (2 Nm).
  4.  
  5. Connect the HVAC wire harness connector to the blend door actuator(s).
  6.  
  7. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  8.  
  9. Reconnect the battery negative cable.
  10.  


CAUTION
On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, 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 or death.


NOTE
The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.


CAUTION
On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, 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.

  1. Disconnect and isolate the battery negative cable.
  2.  
  3. Remove the glove box from the instrument panel, as follows:
    1. Unlatch and open the glove box.
    2.  
    3. Locate the two rubber stop bumpers on the sides of the instrument panel glove box opening.
    4.  
    5. Depress both sides of the glove box bin inwards far enough so that the glove box stops that are integral to each side of the bin can be moved past the rubber stop bumpers.
    6.  
    7. Holding the sides of the glove box bin depressed, roll the glove box downward until the stops molded into the sides of the glove box bin are beyond the rubber stop bumpers, then release the sides of the glove box bin.
    8.  
    9. Remove the three screws that secure the glove box hinge to the instrument panel lower glove box opening reinforcement.
    10.  
    11. Remove the glove box from the instrument panel.
    12.  

  4.  
  5. Reach through the instrument panel glove box opening to access and unplug the wire harness connector from the blend-air door motor.
  6.  
  7. Reach through the instrument panel glove box opening to unlatch the link retainer on the end of the blend-air door motor lever. Remove the link from the retainer.
  8.  
  9. Remove the three screws that secure the blend-air door motor to the top of the distribution duct.
  10.  
  11. Remove the blend-air door motor from the distribution duct.

    Click image to see an enlarged view

    Fig. View of the lever (1), blend-air door motor (2), distribution duct (3), wire connector receptacle (4), screws (5) and link retainer (6)

    View of the lever (1), blend-air door motor (2), distribution duct (3), wire connector receptacle (4), screws (5) and link retainer (6)
  12.  

To install:

  1. Position the blend-air door motor on the top of the distribution duct.
  2.  
  3. Secure the blend-air door motor to the distribution duct with three screws. Tighten the mounting screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Install the link to the retainer on the end of the blend-air door lever. Be certain that the retainer is positioned between the two sets of nubs on the link, then snap the retainer closed

    Click image to see an enlarged view

    Fig. View of the blend-air door lever (1), link (2), nubs (3), boot (4), heater core tubes (5), clip (6) and nut (7)

    View of the blend-air door lever (1), link (2), nubs (3), boot (4), heater core tubes (5), clip (6) and nut (7)
  6.  
  7. Plug in the blend-air door motor wire harness connector.
  8.  
  9. Reinstall the glove box in the instrument panel.
  10.  
  11. Connect the battery negative cable.
  12.  

Dual Zone Passenger's Side



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  4.  
  5. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3).

    Click image to see an enlarged view

    Fig. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3)

    Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3)
  6.  
  7. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3).
  8.  
  9. Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.
  10.  
  11. Remove the blend door actuator and bracket assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.

    Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.
  12.  

To install:

  1. Install the blend door actuator and bracket assembly onto the top of the HVAC housing.
  2.  
  3. Install the screws that secure the blend door actuator and bracket assembly to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Connect the HVAC wire harness connector to the blend door actuator.
    NOTE
    Align the guide pin on the blend door lever with the guides on the blend door linkage during installation of the blend door lever.

  6.  
  7. Install the blend door lever onto the blend door actuator output shaft and the blend door linkage.
  8.  
  9. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  10.  
  11. Reconnect the negative battery cable.
  12.  

Single Zone/Dual Zone Driver's Side



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  4.  
  5. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3).
  6.  
  7. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.

    Click image to see an enlarged view

    Fig. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator

    Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator
  8.  
  9. Remove the blend door actuator from the vehicle.
  10.  

To install:


NOTE
The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

  1. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4).

    Click image to see an enlarged view

    Fig. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4)

    Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4)
  2.  
  3. Install the screws that secure the blend door actuator to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Connect the HVAC wire harness connector to the blend door actuator.
  6.  
  7. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  8.  
  9. Reconnect the negative battery cable.
  10.  

 
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