STEERING COLUMN OPENING SUPPORT BRACKET
REMOVAL
1. Remove the steering column opening cover from
the instrument panel (1) (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
2. Remove the hood release handle from the steering
column opening support bracket (2) (Refer to 23 -
BODY/HOOD/LATCH RELEASE CABLE -
REMOVAL).
3. Disengage the retaining tabs that secure the data
link connector (3) to the steering column opening
support bracket and remove the data link connector
from the bracket.
4. Remove the two screws (4) that secure the steer-
ing column opening support bracket (3) to the
instrument panel (2).
5. Slide the steering column opening support bracket
upward to disengage the two locating tabs (1) and
remove the bracket.
INSTALLATION
1. Position the steering column opening bracket (3)
onto the instrument panel (2) and engage to the
two locating tabs (1).
2. Install the two screws (4) that secure the steering
column opening bracket to the instrument panel.
Tighten the screws to 2.2 Nꞏm (20 in. lbs.).
3. Position the data link connector (3) into the open-
ing in the steering column opening bracket (2) and
fully engage the retaining tabs that secure the con-
nector to the bracket.
4. Install the hood release handle (Refer to 23 -
BODY/HOOD/LATCH RELEASE CABLE - INSTAL-
LATION).
5. Install the steering column opening cover onto the
instrument panel (1) (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - INSTALLATION).
STORAGE BIN
REMOVAL
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. Discon-
nect 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 accidentalairbag deployment and possible
personal injury or death.
NOTE: A storage bin replaces the cup holder in
the instrument panel when the vehicle is equipped
with a floor console.
1. Remove the instrument panel center bezel (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRU-
MENT PANEL CENTER BEZEL - REMOVAL).
2. Removethefloorconsole(Referto23-BODY/IN-
TERIOR/FLOOR CONSOLE - REMOVAL).
3. Remove the four screws (1) that secure the stor-
age bin (2) to the instrument panel and remove the
bin.
INSTALLATION
NOTE: A storage bin replaces the cup holder in
the instrument panel when the vehicle is equipped
with a floor console.
1. Position the storage bin (2) into the instrument
panel.
2. Install the four screws (1) that secure the storage
bin to the instrument panel. Tighten the screws to
2.2 Nꞏm (20 in. lbs.).
3. Install the floor console (Refer to 23 - BODY/INTE-
RIOR/FLOOR CONSOLE - INSTALLATION).
4. Install the instrument panel center bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).
A-PILLAR TRIM/GRAB HANDLE
REMOVAL
1. Using a small flat-bladed tool, carefully open the
two fastener covers (3) located in the a-pillar trim
panel (2).
2. Remove the two bolts (4) that secure the a-pillar
trim panel to the a-pillar (1) and remove the trim
panel.
INSTALLATION
1. Position the locating tab of the A-pillar trim panel
(2) into the slot located in the top of the instrument
panel.
2. Install the A-pillar trim panel onto the A-pillar (1)
and install the two bolts (4). Tighten the bolts to 6
Nꞏm (55 in. lbs.).
3. Close the two fastener covers (3) located in the
A-pillar trim panel.
SEATS
WARNING
WARNINGS - RESTRAINT SYSTEM
WARNING: To avoid personal injury or death, during and following any seat beltorchildrestraintanchor
service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors
for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any
belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle
or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child
restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to
repair a seat belt or child restraint component. Always replace damaged orineffective seat belt and child
restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler
Mopar
Parts Catalog.
WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental
restraint system before attempting any steering wheel, steering column,airbag, seat belt tensioner, impact
sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing further diag-
nosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.
WARNING: To avoid personal injury or death on vehicles equipped with airbags, before performing any
welding operations disconnect and isolate the battery negative (ground)cable and disconnect all wire har-
ness connectors from the Occupant Restraint Controller (ORC). Failure totake the proper precautions could
result in accidental airbag deployment and other possible damage to the supplemental restraint system cir-
cuits and components.
WARNING: To avoid personal injury or death, do not attempt to dismantle an airbag unit or tamper with its
inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures
exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These
materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible com-
pounds. An airbag inflator unit may also contain a gas canister pressurizedtoover2500psi.
WARNING: To avoid personal injury or death, when handling a seat belt tensioner retractor, proper care
should be exercised to keep fingers out from under the retractor cover and away from the seat belt webbing
where it exits from the retractor cover.
WARNING: To avoid personal injury or death, replace all restraint system components only with parts spec-
ified in the DaimlerChrysler Mopar
Parts Catalog. Substitute parts may appear interchangeable, but internal
differences may result in inferior occupant protection.
WARNING: To avoid personal injury or death, the fasteners, screws, and bolts originally used for the
restraint system components must never be replaced with any substitutes.These fasteners have special
coatings and are specifically designed for the restraint system. Any timea new fastener is needed, replace
it with the correct fasteners provided in the service package or specifiedin the DaimlerChrysler Mopar
Parts Catalog.
WARNING: To avoid personal injury or death, when a steering column has an airbag unit attached, never
place the column on the floor or any other surface with the steering wheel orairbag unit face down.
WELD LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
FENDER BRACE, CLOSURE TUBE AND FRAME MOUNTING BRACKET TO FRONT
FENDER SUPPORT, FRONT FENDER AND RADIATOR TUBE46
STEERING COLUMN SUPPORT, CONNECTOR WIRING BRACKET AND WELD NUTS
TO LOWER PLENUM PANEL47
WIPER ATTACHING WELD NUTS AND VACUUM RESERVOIR ATTACHING STUDS TO
COWL PAR PANEL48
DASH PANEL TO FRONT FLOOR PAN 49
DASH PANEL TO LOWER PLENUM PANEL 50
LOWER PLENUM PANEL TO COWL BACK PANEL 51
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL
MOUNTING BRACKET, AND WELD NUTS TO COWL SIDE PANEL - LEFT SIDE52
DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PA N E L - L E F T S I D E53
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL
MOUNTING BRACKET AND WELD NUTS TO COWL SIDE PANEL - RIGHT SIDE54
DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PANEL - RIGHT SIDE55
REINFORCEMENT AND HEADLAMP MOUNTING PANEL TO OUTER FENDER PANEL 56
SEAT MOUNTING FRONT BRACKETS TO SEAT MOUNTING FRONT CROSSMEMBER
TO FRONT FLOOR PAN57
AIR BAG MODULE BRACKET SHIFTER MOUNTING PLATE AND REAR FLOOR PANEL
TO FRONT FLOOR PAN58
RIGHT TO LEFT REAR FLOOR CROSSMEMBER AND RIGHT TO LEFT SEAT
MOUNTING CROSSMEMBER59
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL60
SEAT MOUNTING FRONT CROSSMEMBER TO FRONT FLOOR PAN TO UNDERBODY
SUPPORT61
FRONT SEAT MOUNTING CROSSMEMBERS TO FRONT SEAT MOUNTING BRACKET
TO FRONT FLOOR PAN62
REAR FLOOR CROSSMEMBERS TO REAR FLOOR PAN 63
FLOOR SILL TO FRONT SEAT MOUNTING CROSSMEMBER, FRONT AND REAR
FLOOR PAN64
AIR BAG MODULE BRACKET, SHIFTER MOUNTING PLATE AND FRONT SEAT
MOUNTING CROSSMEMBER TO FRONT FLOOR PAN65
REAR SEAT MIDDLE MOUNTING PLATE TO REAR FLOOR PAN TO FRONT FLOOR
PA N66
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL67
LEFT REAR CROSSMEMBER TO RIGHT REAR CROSSMEMBER TO REAR FLOOR
PA N68
STORAGE BIN TO RIGHT AND LEFT REAR FLOOR CROSSMEMBER TO REAR
FLOOR PAN69
HVAC - SERVICE INFORMATION
DESCRIPTION
A manually controlled single zone type heating-air conditioning system or a manually controlleddualzonetypeheat-
ing-air conditioning system is available on this model.
To maintain the performance level of the heating, ventilation and air conditioning (HVAC) system, the engine cooling
system must be properly maintained. The use of a bug screen is not recommended. Any obstructions in front of the
radiator or A/C condenser will reduce the performance of the A/C and enginecooling systems.
The engine cooling system includes the radiator, thermostat, radiator hoses and the engine coolant pump. Refer to
7 - Cooling for more information before opening or attempting any service to the engine cooling system.
All vehicles are equipped with a common heater, ven-
tilation and air conditioning (HVAC) housing (1). The
system combines air conditioning, heating, and venti-
lating capabilities in a single unit housing mounted
within the passenger compartment under the instru-
ment panel. The HVAC housing includes:
Blend-air door(s) and actuator(s) (2)
Recirculation-air door and actuator (3)
A/C evaporator (4)
Blower motor (5)
Blower motor resistor (6)
Evaporator temperature sensor (7)
Heater core (8)
Mode-air doors and actuators (9)
Based upon the system and mode selected, conditioned air can exit the HVAC housing through one or a combi-
nation of the three main housing outlets: defrost, panel or floor. The defrost and the panel outlets are located on the
top of the housing and, the floor outlet is located on the bottom of the housing. Once the conditioned air exits the
HVAC housing, it is further directed through molded plastic ducts to the various outlets within the vehicle interior.
These outlets and their locations are as follows:
Defroster Outlet- A single large defroster outlet is located in the center of the instrumentpanel top cover,
near the base of the windshield.
Side Window Demister Outlets- There are two side window demister outlets, one is located at each out-
board end of the instrument panel top cover, near the belt line at the A-pillars.
Panel Outlets- There are four panel outlets in the instrument panel, one located near each outboard end of
the instrument panel facing the rear of the vehicle and two located near thetop of the instrument panel center
bezel.
Front Floor Outlets- There are two front floor outlets, one located above each side of the floorpanel center
tunnel near the dash panel.
Rear Outlets- On Mega Cab models there are two outlets located at the rear of the center front seat.
OPERATION
Both the manual temperature control (MTC) single zone and dual zone heating-A/C system are blend-air type sys-
tems. In a blend-air heating-A/C, a blend-air door controls the amount of conditioned air that is allowed to flow
through, or around, the heater core.In the available dual zone system, twoblend-air doors are used to provide
completely independent side-to-side temperature control of the discharge air. The temperature control(s) determines
the discharge air temperature(s) by operating the blend door actuator(s), which move the blend-air door(s). This
design allows almost immediate control of output air temperature(s).
The heating-A/C systems pulls outside (ambient) air
through the cowl opening at the base of the wind-
shield, then into the air inlet housing above the heat-
ing, ventilation and air conditioning (HVAC) housing.
On models equipped with A/C, the air passes through
the A/C evaporator (3). Air flow can be directed either
through or around the heater core (1). This is done by
adjusting the blend-air door(s) (2) with the temperature
control(s) located on the A/C-heater control in the
instrument panel. The air flow can then be directed
from the panel, floor and defrost outlets in various
combinations using the mode control located on the A/C-heater control. Air flow velocity can be adjusted with the
blower speed control located on the A/C-heater control.
On all models, the outside air intake can be shut off by selecting the Recirculation Mode with the mode control. This
will operate a electrically actuated recirculation-air door (4) that closes off the fresh air intake and recirculates the air
that is already inside the vehicle.
On models with A/C, the A/C compressor can be engaged in any mode by pressingthe snowflake, A/C on/off but-
ton. It can also be engaged by placing the mode control in the mix to defrost positions. This will remove heat and
humidity from the air before it is directed through or around the heater core. The mode control on the A/C-heater
control is used to also direct the conditioned air to the selected system outlets. The mode control uses electric
actuators to control the mode-air doors (5 and 6).
The defroster outlet receives airflow from the HVAC housing through the molded plastic defroster duct, which con-
nects to the HVAC housing defroster outlet. The airflow from the defrosteroutlets is directed by fixed vanes in the
defroster outlet grilles and cannot be adjusted. The defroster outlet grilles are integral to the instrument panel top
cover.
The side window demister outlets receive airflow from the HVAC housing through the molded plastic defroster duct
and two molded plastic demister ducts. The airflow from the side window demister outlets is directed by fixed vanes
in the demister outlet grilles and cannot be adjusted. The side window demister outlet grilles are integral to the
instrument panel. The demisters direct air from the HVAC housing through the outlets located on the top corners of
the instrument panel. The demisters operate when the mode control knob is positioned in the floor-defrost and
defrost-only settings. Some air may be noticeable from the demister outlets when the mode control is in the bi-level
to floor positions.
The panel outlets receive airflow from the HVAC housing through a molded plastic main panel duct, center panel
duct and two end panel ducts. The two end panel ducts direct airflow to the left and right instrument panel outlets,
while the center panel duct directs airflow to the two center panel outlets. Each of these outlets can be individually
adjusted to direct the flow of air.
The floor outlets receive airflow from the HVAC housing through the floor distribution duct. The front floor outlets are
integral to the molded plastic floor distribution duct, which is secured to the bottom of the housing. The floor outlets
cannot be adjusted.
NOTE: It is important to keep the air intake opening clear of debris. Leaf particles and other debris that is
small enough to pass through the cowl opening screen can accumulate withinthe HVAC housing. The
closed, warm, damp and dark environment created within the housing is ideal for the growth of certain
molds, mildews and other fungi. Any accumulation of decaying plant matterprovides an additional food
source for fungal spores, which enter the housing with the fresh intake-air. Excess debris, as well as objec-
tionable odors created by decaying plant matter and growing fungi can be discharged into the passenger
compartment during heater-A/C operation if the air intake opening is not kept clear of debris.
The A/C system on models so equipped is designed for the use of non-CFC, R-134a refrigerant and uses an A/C
fixedorificetubelocatedintheliquidlinetometertheflowofrefrigerant to the A/C evaporator. The A/C evaporator
cools and dehumidifies the incoming air prior to blending it with the heated air. To maintain minimum evaporator
temperature and prevent evaporator freezing, an evaporator temperaturesensor is used to supply evaporator tem-
perature input to the A/C-heater control. The powertrain control module (PCM) cycles the A/C compressor clutch off
and on as necessary to protect the A/C system from evaporator freezing and optimize A/C system performance.