Front Area Service Procedure

Front Area (Dashboard, Lower Windshield, Steering Wheel/Column, Kick Panels, Pedals)

Includes: Dash pad and instrument cluster, dash internal structure and components, windshield to dash interface area, audio and HVAC controls and vents, glove box, steering wheel or column mounted controls, kick panels and pedal areas.

NOTE: Read through all of the incidents that apply to the incident area in the vehicle. Some repairs may need to be done in combination with others.

WARNING: If servicing a part of the SRS (air bag) is needed, always turn the ignition switch off, disconnect both battery cables and wait at least three (3) minutes before performing the service.

Incident 1: Buzz from the security monitor area.

Verify:
This noise may occur during initial acceleration from a stop.

Isolate:
While on a test drive, this incident can be temporarily stopped by pressing down on the instrument panel, around the security monitor. This incident may be caused by contact between the security monitor harness and the air duct of the side ventilator.

Repair:
1. Remove the left hand side defroster grille.




2. Disconnect the security monitor from its harness (see Figure 1).
3. Wrap the harness in urethane pad (P/N 76268-9E005).
4. Reinstall the security monitor and defroster duct.

Recheck:
Test the vehicle as described above to ensure the repair is complete.


Incident 2: Buzz from left side defroster duct.

Verify:
This noise may occur while the engine is at idle.

Isolate:
This incident can be temporarily stopped by pressing on the left side of the instrument panel. This incident may be caused by contact between the left side defroster duct and the under side of the instrument panel.

Repair:

1. Remove the left side defroster duct nozzle.




2. Add urethane pad (P/N 76268-9E005) between the defroster duct and the instrument panel (see Figure 2).
3. Reinstall the defroster nozzle.

Recheck:
Test the vehicle as described above to ensure the repair is complete.

Incident 3: Buzz from behind the glove box.

Verify:
This noise may occur when driving on pavement or rough roads at speeds over 15 MPH.

Isolate:
While on a test drive, this incident may be verified by touching the upper part of the instrument panel, above the glove box. This incident may be caused by contact between the passenger side air bag bracket and the right side ventilator air duct.

Repair:
1. Remove the glove box.



2. Apply urethane pad (P/N 76268-9E005) to the ventilator duct as shown in Figure 3.
3. Reinstall the glove box.

Recheck:
Test the vehicle as described above to ensure the repair is complete.


Incident 4: Buzz from the right side ventilator.

Verify:
This noise may occur when driving on pavement or rough roads at speeds over 15 MPH.

Isolate:



While on a test drive, this incident may be felt or temporarily stopped by pressing on the ventilator grille. This incident may be caused by the knee protection bar (see Figure 4) contacting a lower mounting flange of the ventilator grille.

Repair:
1. Remove the glove box.
2. Remove the knee protector bar.




3. Add urethane pad (P/N 76268-9E005) to the knee protector bar, at the point shown in Figure 5.
4. Reinstall the glove box.

Recheck:
Test the vehicle as described above to ensure the repair is complete.

Incident 5: Rattle from the right side ventilator/glove box area.

Verify:
This noise may occur when driving on pavement or rough roads at speeds over 15 MPH.

Isolate:
While on a test drive, this incident may be felt or temporarily stopped by pressing upward on the right upper corner of the glove box. This incident may be caused by the glove box contacting the knee protection bar.

Repair:
1. Remove upper screws securing the glove box.




2. Pull the glove box down slightly as shown in Figure 7a. Mark the area of the glove box shown in Figure 7b.
3. Remove the glove box and trim the plastic as marked in step 2.




4. Add urethane pad (P/N 76884-71L02) to the knee protector bar, at the point shown in Figure 8.
5. Reinstall the glove box.

Recheck:
Test the vehicle as described above to ensure the repair is complete.

Incident 6: Rattle from the middle of the instrument panel/defroster ducts.

Verify:
This noise may occur when driving on pavement or rough roads at speeds from 15 to 25 MPH.

Isolate:



This incident may be stopped or diminished by pressing on the center defroster duct. This incident may be caused by contact of the side defroster ducts and the front defroster duct (see Figure 9).

Repair:
1. Remove the driver front air bag module and steering wheel (see previous WARNING,).
2. Remove the steering column cover and combination meter.
3. Remove the glove box assembly.
4. Remove the passenger front air bag module (see WARNING).
6. Remove both side defroster air ducts.




7. Install urethane (P/N 76268-9E005) as shown in Figure 10
8. Reinstall both side defroster ducts, passenger front air bag module, glove box assembly, combination meter, steering column cover, steering wheel and driver front air bag module.

Recheck:
Test the vehicle as described above to ensure the repair is complete.

Incident 7: Buzz from behind the dash/inside the engine compartment.

Verify:
This noise may occur while the engine is at idle. The incident is more noticeable when the A/C compressor is on.

Isolate:



This incident may be stopped or diminished by pressing down on or pulling up on the hood support rod. This incident may be caused by contact between the hood support rod and its grommet (see Figure 11).

Repair:
1. Support the hood with a temporary prop rod.
2. Remove the hood support rod and its grommet.
3. Slide the grommet up the rod.
4. Wrap the portion of the rod that contacts the grommet with felt cloth tape (P/N 68239- 13E00).
5. Reinstall the support rod and the grommet.

Recheck:
Test the vehicle as described above to ensure the repair is complete.

Incident 8: Rattle from driver's foot well area.

Verify:
This noise may occur while driving, especially when accelerating and manually changing gears.

Isolate:



This incident may be stopped or diminished by pulling the air cleaner away from the left strut tower. This incident may be caused by contact between the air cleaner and the left strut tower (see Figure 12).

Repair:
1. Remove the air cleaner lid.
2. Remove the existing foam tape, if still attached.
3. Cut urethane pad (P/N 76884-71L02) in half to make two long rectangles.
4. Stick one half on top of the other to make a double thick pad.
5. Clean the area of the air cleaner lid where the strut tower contacts it.
6. Apply the double thick urethane pad you just made to the area of the air cleaner lid you just cleaned.
7. Reinstall the air cleaner lid.

CAUTION: Before installing the air cleaner lid, make sure that there is no debris in the lid or on the air filter. Engine damage will occur.

Recheck:
Test the vehicle as described above to ensure the repair is complete.