Y STI ISTRUT TTS SRVI IRTI... 2 RUTIS... 2 recaution for Supplemental Restraint System (SRS) "IR " and "ST T R-T- SIR"...2 RRTI... 3 Special Service Tool...3 ommercial Service Tool...3 SQU RTT TRU I- SIS... 4 Work low...4 eneric Squeak and Rattle Troubleshooting...6 iagnostic Worksheet...8 ISTRUT SSY...10 Instrument anel...10 luster id...11 ombination eter...12 Instrument ower anel...12 Steering olumn over...12 luster id...13 luster id...13 enter Stack Trim anel...13 love ox...14 TR S SSY...16 omponent...16 Removal...17 isassembly...17 ssembly...19 Installation...19-1
SRVI IRTI RUTIS RUTIS recaution for Supplemental Restraint System (SRS) "IR " and "ST T R-TSIR" II:0000000001718737 The Supplemental Restraint System such as IR and ST T R-TSIR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and S section of this Service anual. WRI: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized ISS/IIITI dealer. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SRS section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. -2
RRTI Special Service Tool RRTI II:0000000001718738 The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name (-39570) hassis ear escription ocating the noise ST839 (-43980) ISS Squeak and Rattle kit Repairing the cause of noise ST840 ommercial Service Tool II:0000000001718739 (ent-oore o.) Tool name (-39565) ngine ear escription ocating the noise SII0995 ower Tool oosening bolts and nuts I0191-3
SQU RTT TRU ISIS < SRVI IRTI > SQU RTT TRU ISIS Work low II:0000000001718740 ST842 USTR ITRVIW Interview the customer, if possible, to determine the conditions that exist when the noise occurs. Use the iagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any customer's comments; refer to -8, "iagnostic Worksheet". This information is necessary to duplicate the conditions that exist when the noise occurs. The customer may not be able to provide a detailed description or the location of the noise. ttempt to obtain all the facts and conditions that exist when the noise occurs (or does not occur). If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is concerned about. This can be accomplished by test driving the vehicle with the customer. fter identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics are provided so the customer, service adviser and technician are all speaking the same language when defining the noise. - Squeak (ike tennis shoes on a clean floor) Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping. - reak (ike walking on an old wooden floor) reak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch dependent on materials/often brought on by activity. - Rattle (ike shaking a baby rattle) Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing clip or fastener/incorrect clearance. - nock (ike a knock on a door) nock characteristics include hollow sounding/sometimes repeating/often brought on by driver action. - Tick (ike a clock second hand) Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver action or road conditions. - Thump (eavy, muffled knock noise) Thump characteristics include softer knock/dead sound often brought on by activity. - uzz (ike a bumblebee) uzz characteristics include high frequency rattle/firm contact. ften the degree of acceptable noise level will vary depending upon the person. noise that you may judge as acceptable may be very irritating to the customer. Weather conditions, especially humidity and temperature, may have a great effect on noise level. UIT T IS TST RIV If possible, drive the vehicle with the customer until the noise is duplicated. ote any additional information on the iagnostic Worksheet regarding the conditions or location of the noise. This information can be used to duplicate the same conditions when you confirm the repair. -4
SQU RTT TRU ISIS If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to duplicate the noise with the vehicle stopped by doing one or all of the following: 1. lose a door. 2. Tap or push/pull around the area where the noise appears to be coming from. 3. Rev the engine. 4. Use a floor jack to recreate vehicle twist. 5. t idle, apply engine load (electrical load, half-clutch on /T model, drive position on /T model). 6. Raise the vehicle on a hoist and hit a tire with a rubber hammer. rive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the vehicle body. RT SRVI UTIS fter verifying the customer concern or symptom, check SIST for Technical Service ulletins (TSs) related to that concern or symptom. If a TS relates to the symptom, follow the procedure to repair the noise. T T IS ITIY T RT US 1. arrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (hassis ar: -39570, ngine ar: -39565, and mechanics stethoscope). 2. arrow down the noise to a more specific area and identify the cause of the noise by: Removing the components in the area that you suspect the noise is coming from. o not use too much force when removing clips and fasteners, otherwise clips and fasteners can be broken or lost during the repair, resulting in the creation of new noise. Tapping or pushing/pulling the component that you suspect is causing the noise. o not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only temporarily. eeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the noise. lacing a piece of paper between components that you suspect are causing the noise. ooking for loose components and contact marks. Refer to -6, "eneric Squeak and Rattle Troubleshooting". RIR T US If the cause is a loose component, tighten the component securely. If the cause is insufficient clearance between components: - Separate components by repositioning or loosening and retightening the component, if possible. - Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane tape. ISS Squeak and Rattle it (-43980) is available through your authorized ISS arts epartment. UTI: o not use excessive force as many components are constructed of plastic and may be damaged. lways check with the arts epartment for the latest parts information. The following materials are contained in the ISS Squeak and Rattle it (-43980). ach item can be ordered separately as needed. URT S [1.5 mm (0.059 in) thick] Insulates connectors, harness, etc. 76268-9005: 100 x 135 mm (3.94 x 5.31 in)/76884-7101: 60 x 85 mm (2.36 x 3.35 in)/76884-7102: 15 x 25 mm (0.59 x 0.98 in) ISUTR (oam blocks) Insulates components from contact. an be used to fill space behind a panel. 73982-9000: 45 mm (1.77 in) thick, 50 x 50 mm (1.97 x 1.97 in)/73982-50y00: 10 mm (0.39 in) thick, 50 x 50 mm (1.97 x 1.97 in) ISUTR (ight foam block) 80845-7100: 30 mm (1.18 in) thick, 30 x 50 mm (1.18 x 1.97 in) T T T Used to insulate where movement does not occur. Ideal for instrument panel applications. 68370-4000: 15 x 25 mm (0.59 x 0.98 in) pad/68239-1300: 5 mm (0.20 in) wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UW (T) T Insulates where slight movement is present. Ideal for instrument panel applications. -5
SQU RTT TRU ISIS < SRVI IRTI > SII RS Used in place of UW tape that will be visible or not fit. ote: Will only last a few months. SII SRY Use when grease cannot be applied. UT T Use to eliminate movement. IR T RIR onfirm that the cause of a noise is repaired by test driving the vehicle. perate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the iagnostic Worksheet. eneric Squeak and Rattle Troubleshooting Refer to Table of ontents for specific component removal and installation information. II:0000000001718741 ISTRUT ost incidents are caused by contact and movement between: 1. The cluster lid and instrument panel 2. crylic lens and combination meter housing 3. Instrument panel to front pillar garnish 4. Instrument panel to windshield 5. Instrument panel mounting pins 6. Wiring harnesses behind the combination meter 7. / defroster duct and duct joint These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. ost of these incidents can be repaired by applying felt cloth tape or silicone spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness. UTI: o not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will not be able to recheck the repair. TR S omponents to pay attention to include: 1. Shifter assembly cover to finisher 2. / control unit and cluster lid 3. Wiring harnesses behind audio and / control unit The instrument panel repair and isolation procedures also apply to the center console. RS ay attention to the: 1. inisher and inner panel making a slapping noise 2. Inside handle escutcheon to door finisher 3. Wiring harnesses tapping 4. oor striker out of alignment causing a popping noise on starts and stops Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from the ISS Squeak and Rattle it (-43980) to repair the noise. TRU Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner. In addition look for: 1. Trunk lid bumpers out of adjustment 2. Trunk lid striker out of adjustment 3. The trunk lid torsion bars knocking together 4. loose license plate or bracket -6
SQU RTT TRU ISIS ost of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) causing the noise. SUR/II oises in the sunroof/headlining area can often be traced to one of the following: 1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise 2. Sun visor shaft shaking in the holder 3. ront or rear windshield touching headliner and squeaking gain, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape. VR S (RT RR) verhead console noises are often caused by the console panel clips not being engaged correctly. ost of these incidents are repaired by pushing up on the console at the clip locations until the clips engage. In addition look for: 1. oose harness or harness connectors. 2. ront console map/reading lamp lens loose. 3. oose screws at console attachment points. STS When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when the noise is present. These conditions should be duplicated when verifying and isolating the cause of the noise. ause of seat noise include: 1. eadrest rods and holder 2. squeak between the seat pad cushion and frame 3. The rear seatback lock and bracket These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs. ost of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area. UR Some interior noise may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. auses of transmitted underhood noise include: 1. ny component mounted to the engine wall 2. omponents that pass through the engine wall 3. ngine wall mounts and connectors 4. oose radiator mounting pins 5. ood bumpers out of adjustment 6. ood striker out of adjustment These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best method is to secure, move or insulate one component at a time and test drive the vehicle. lso, engine R or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or insulating the component causing the noise. -7
SQU RTT TRU ISIS < SRVI IRTI > iagnostic Worksheet II:0000000001718742 I0072-8
SQU RTT TRU ISIS I0071-9
ISTRUT SSY < SRVI IRTI > ISTRUT SSY Instrument anel II:0000000001718743 TS II2487 1. Steering member assembly 2. efrost grille 3. Speaker cover 4. eter cover 5. Instrument panel 6. ombination meter -10
RV ISTRUT SSY 7. luster lid 8. vent grille 9. Instrument panel side finisher 10. Instrument lower panel 11. Storage bin 12. Steering column upper cover 13. Steering column lower cover 14. Ignition switch bezel 15. nee protector 16. Instrument panel side cover 17. Instrument panel side cover R 18. enter stack trim panel 19. enter lower trim 20. V door 21. V deck 22. udio unit 23. luster lid 24. V switch 25. ssistant under cover panel 26. love box assembly 27. ront air control 28. R vent grille 29. Instrument panel side finisher R 30. isplay unit 31. luster lid 32. Speaker cover R 1. isconnect the battery negative and positive terminals. 2. Remove cluster lid. Refer to -13, "luster id ". 3. Remove steering column. Refer to S-9. 4. Remove combination meter. Refer to -12, "ombination eter". 5. Remove display unit. Refer to V-148, "Removal and Installation". 6. isconnect center speaker. 7. isconnect S antenna. 8. Remove defrost grille. 9. Remove front pillar finishers and R. 10. Remove front speakers. Refer to V-72, "Removal and Installation". 11. Remove instrument panel assembly. ISTTI luster id RV 1. Remove instrument panel side finisher. II:0000000001718744 II2484 2. Remove screw (1) and vent grille. II2485 3. Remove upper and lower steering column covers. 4. ull to release clips and remove cluster lid. -11
ISTRUT SSY < SRVI IRTI > ISTTI ombination eter II:0000000001718745 RV 1. isconnect battery negative terminal. 2. Remove cluster lid. Refer to -11, "luster id ". 3. Remove the combination meter, using power tool. 4. isconnect combination meter electrical connectors. ISTTI Instrument ower anel II2486 II:0000000001718746 RV 1. isconnect battery negative terminal. 2. Remove the ignition switch bezel (1), screws (), and instrument lower panel (2). II2479 3. isconnect harness connectors. ISTTI Steering olumn over II:0000000001718747 RV 1. Remove tilt lever knob from tilt lever by inserting a suitable tool into slot of tilt knob, then depress tab and withdraw tilt lever knob. WI0061-12
ISTRUT SSY 2. Remove the screws and the steering column upper and lower covers. ISTTI luster id RV UTI: To prevent damage, place shop cloths onto surrounding parts. 1. isconnect battery negative and positive terminals. 2. Remove center stack trim panel. Refer to -13, "enter Stack Trim anel". 3. Remove selector knob. Refer to T-215, "Removal and Installation". 4. ull up to release cluster lid clips. 5. isconnect harness connectors and remove cluster lid. ISTTI luster id RV 1. ull up to release clips and remove cluster lid. II:0000000001718748 II:0000000001718749 ISTTI enter Stack Trim anel RV 1. Remove instrument lower panel. Refer to -12, "Instrument ower anel ". 2. Remove glove box. Refer to -14, "love ox". 3. Remove the screws () and center lower trim (1). II2488 II:0000000001718750 II2480-13
ISTRUT SSY < SRVI IRTI > 4. Remove center stack lower trim R and. II2481 5. Remove lower screws using power tool. II2482 6. ull to release clips and remove center stack trim panel. 7. isconnect both power point electrical connectors. II2483 ISTTI love ox II:0000000001718751 RV UTI: To prevent damage, place shop cloths onto surrounding parts. 1. lace the door weatherstrip by the glove box aside. -14
ISTRUT SSY 2. Remove glove box screws using power tool. 3. arefully remove the clips by prying loose. 4. isconnect glove box lamp harness. UTI: To prevent damage, do not let the glove box hang from glove box lamp harness. ISTTI II2478-15
TR S SSY omponent TR S SSY II:0000000001718752 II2468 1. up holder 2. Top cover assembly 3. R console side trim panel 4. lip 5. R case 6. ront bin latch assembly 7. ront bin assembly 8. ront bin latch handle 9. onsole mat 10. case 11. console side trim panel 12. Storage bin insert 13. Storage bin door assembly 14. Rear console trim cover -16
Removal TR S SSY 1. Remove storage bin insert (1) and console mat (2). II:0000000001718753 2. Remove top cover assembly. II2470 3. pen the front bin (1), remove the bolts (), and center console (2). II2471 isassembly 1. Remove center console. Refer to -17, "Removal". II2473 II:0000000001718754-17
2. Remove front bin assembly. TR S SSY II2472 3. Remove rear console trim cover. II2474 4. Remove R and console side trim panels. II2475 5. Remove storage bin door assembly. II2476 6. Remove screws and split R from case. II2477-18
ssembly ssembly is in the reverse order of disassembly Installation TR S SSY II:0000000001718755 II:0000000001718756-19