Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Instrument Panel and Pad

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REMOVAL & INSTALLATION





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Fig. Fig. 1: Identification of some of the components related to instrument panel removal

All Models

See Figures 1 through 5

This is a general procedure; certain steps may need alteration for your particular vehicle.

  1. Disconnect the negative battery cable.
  2.  


WARNING
Before servicing a vehicle equipped with an air bag system, it is vital to read the precautions in Chassis Electrical of this guide to avoid accidental injury or death.

  1. Disable the air bag system, as described in Chassis Electrical .
  2.  
  3. Remove the center console.
  4.  
  5. Remove the lower steering column cover by loosening the mounting screws.
  6.  
  7. Remove the glove box.
  8.  
  9. Detach the wiring harness connectors from the heater unit and the blower motor assembly.
  10.  
  11. For Samurai models, remove the steering column as follows:
    1. Remove the combination switch, as described in Suspension & Steering of this repair guide.
    2.  
    3. Open the hood.
    4.  
    5. Remove the upper-to-lower steering shaft attaching bolt.
    6.  
    7. Loosen the steering column retaining bolts at the firewall and lower instrument panel brace.
    8.  
    9. Remove the steering column from the vehicle.
    10.  

  12.  
  13. For Sidekick, Tracker, Sidekick Sport and X-90 models, remove the steering column as follows:
    1. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch.
    2.  
    3. Open the hood.
    4.  
    5. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft.
    6.  
    7. Loosen all of the steering column-to-firewall and instrument panel brace bolts.
    8.  
    9. If equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch.
    10.  
    11. Remove the steering column from the vehicle.
    12.  

  14.  


WARNING
Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical-personal injury may be the result.

  1. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster.
  2.  
  3. Remove the hood latch handle.
  4.  
  5. Remove the radio, the heater control panel and the heater control cables from the instrument panel.
  6.  



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Fig. Fig. 1: Before removing the mounting fasteners, be sure to detach and label all of the wiring harness connectors from the instrument panel-Samurai model shown



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Fig. Fig. 2: Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly ...



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Fig. Fig. 3: ... then remove the upper cover plates and loosen the remaining mounting fasteners

  1. Disconnect and label all wiring harness connectors from the instrument panel.
  2.  
  3. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners
  4.  
  5. Have an assistant help you carefully lift the instrument panel up and out of the vehicle. When separating the instrument panel from the firewall, ensure that all of the cables, wires and hoses are disconnected form the instrument panel.
  6.  

To install:
  1. Have an assistant help you position the instrument panel in the vehicle. When installing the instrument panel on the firewall, ensure that all of the cables, wires and hoses are routed properly.
  2.  
  3. Install and tighten the instrument panel mounting screws and bolts.
  4.  
  5. Reattach all wiring harness connectors to the instrument panel.
  6.  
  7. Install the radio, the heater control panel and the heater control cables. Be sure to adjust the heater control cables as described in Chassis Electrical of this repair guide.
  8.  
  9. Install the hood latch handle.
  10.  
  11. Install the instrument cluster, then connect the cable to the speedometer.
  12.  
  13. For Samurai models, install the steering column as follows:
    1. Install the steering column in the vehicle.
    2.  
    3. Install and tighten the steering column retaining bolts to 97-150 inch lbs. (11-17 Nm).
    4.  
    5. Install the upper-to-lower steering shaft attaching bolt. Tighten the bolt to 177-265 inch lbs. (20-30 Nm).

      Click image to see an enlarged view

      Fig. Fig. 4: During steering column installation, ensure that the mounting bolts are tightened to the proper values-Samurai model shown

    6.  
    7. Install the combination switch, as described in Suspension & Steering of this repair guide.
    8.  

  14.  
  15. For Sidekick, Tracker, Sidekick Sport and X-90 models, install the steering column as follows:
    1. Install the steering column in the vehicle.
    2.  
    3. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw.
    4.  
    5. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 221 inch lbs. (25 Nm).
    6.  
    7. Install and tighten the steering column shaft joint bolt to 221 inch lbs. (25 Nm).
    8.  
    9. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch.
    10.  

  16.  
  17. Reattach the wiring harness connectors to the heater unit and the blower motor assembly.
  18.  
  19. Install the glove box.
  20.  
  21. Install the lower steering column cover.
  22.  
  23. Install the center console.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Enable the air bag system, as described in Chassis Electrical .
  28.  

 
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