Opel Insignia: Repair Instructions

Wire to Wire Repair - Steering

Special Tools

• EL-38125-10 Splice Sleeve Crimping Tool (non GMNA)
• J-38125-5A Ultra Torch Special Tool
• J-38125-8 Splice Sleeve Crimping Tool (GMNA)

For equivalent regional tools, refer to Special Tools.

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: The DuraSeal splice sleeves have the following 2 critical features:

• A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.
• A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

Use only DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except high voltage and specialty cables. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

Splice Sleeve Selection

NOTE: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

• Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
• Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.
• Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

3. Strip the insulation:

• When adding a length of wire to the existing harness, use the same size wire as the original wire.
• Perform one of the following items in order to find the correct wire size:
  • Find the wire on the schematic and convert to regional wiring gauge size.
  • If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.
• Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.
• Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
• If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

6.

The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

7.

The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under crimp tool nest color).

9.

Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

10.

Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

12.

Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Weatherpack™ Wiring Repair

NOTE: Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

1. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

2. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.

3. Using the heat torch, apply heat to the crimped area of the barrel.

4.

Start in the middle and gradually move the heat barrel to the open ends of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

5.

Tape the extra terminated lead(s) back into the harness.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

Connector Reconnection - Steering

Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools.

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent.

An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

• Loose, corroded, or painted terminal stud/fastener
• Wiring broken inside the insulation
• Poor connection between the male and female terminal at a connector
• A terminal not seated all the way into the connector body
• Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.
• Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.
• Wiring that comes in contact with hot or exhaust components
• Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.
• Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.
• Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel 760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals.

Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter.

Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves.

Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side.

Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

• Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Power Distribution Schematics.
• Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point (screw or stud). Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Ground Distribution Schematics.

Temperature Sensitivity

• An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.
• Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the following:
  • High ambient temperatures
  • Underhood/engine generated heat
  • Circuit generated heat due to a poor connection, or high electrical load
  • Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
  • Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.
  • The condition only occurs on a cold start.
  • The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern that is temperature related.
• If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

• A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc. - These components may induce electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch - These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.
• Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. - These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories.
• Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.
• The generator may be allowing AC noise into the electrical system.

Incorrect Control Module

• There are only a few situations where reprogramming a control module is appropriate:
  • A new service control module is installed.
  • A control module from another vehicle is installed.
  • Revised software/calibration files have been released for this vehicle.

NOTE: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern.

• Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming.

Upper Intermediate Steering Shaft Replacement

Removal Procedure

1.

Upper Intermediate Steering Shaft Upper Bolt(1) - Remove.

2. Upper Intermediate Steering Shaft(2)@Steering Column - Separate.

3.

Release the upper intermediate steering shaft boot (1) from the retaining tabs (2) on the intermediate steering shaft inner boot.

4.

Slide the upper intermediate steering shaft boot (1) upwards to expose the intermediate steering shaft upper bolt.

5. Intermediate Steering Shaft Upper Bolt(2) - Remove.

6. Upper Intermediate Steering Shaft(3)@Intermediate Steering Shaft - Separate.

7. Remove the upper intermediate steering shaft (1) and upper intermediate steering shaft boot as an assembly from the vehicle.

Installation Procedure

1. Position the upper intermediate steering shaft (1) and upper intermediate steering shaft boot as an assembly in the vehicle.

2.

Upper Intermediate Steering Shaft(3)@Intermediate Steering Shaft - Install.

CAUTION: Refer to Fastener Caution.

3. Intermediate Steering Shaft Upper Bolt(2) - Install and tighten 39 N.m (29 lb ft).

1. Clean the threads of the bolt and mating threads with denatured alcohol or equivalent and allow to dry.
2. Apply thread locking adhesive to the bolt. Adhesives, Fluids, Lubricants, and Sealers

4. Slide the upper intermediate steering shaft boot (1) downwards and align the boot to the intermediate steering shaft inner boot.

5.

Secure the upper intermediate steering shaft boot (1) with the retaining tabs (2) on the intermediate steering shaft inner boot.

6.

Upper Intermediate Steering Shaft(2)@Steering Column - Install.

7. Upper Intermediate Steering Shaft Upper Bolt(1) - Install and tighten 42 N.m (31 lb ft).

1. Clean the threads of the bolt and mating threads with denatured alcohol or equivalent and allow to dry.
2. Apply thread locking adhesive to the bolt.

Intermediate Steering Shaft Boot Replacement (Inner)

Removal Procedure

1.

Upper Intermediate Steering Shaft(3)@Intermediate Steering Shaft - Disconnect.

2. Upper Intermediate Steering Shaft(3) & Intermediate Steering Shaft Boot- Upper(1) - Position aside.

3.

Intermediate Steering Shaft Boot Bolt- Inner(1) - Remove[3x].

4. Lift the lip of the intermediate steering shaft inner boot and release the boot from the intermediate steering shaft pass through.

5.

Intermediate Steering Shaft Boot- Inner(1) - Remove.

Installation Procedure

1.

WARNING: Ensure the bearing in the intermediate steering shaft outer boot does NOT become dislodged while installing the intermediate steering shaft inner boot. If the bearing dislodges then binding in the steering system may occur, causing difficulty in steering the vehicle.

If equipped, inspect the intermediate steering shaft outer boot bearing (1) and ensure the bearing has NOT become dislodged.

If the bearing is dislodged, install the bearing in the outer boot correctly before proceeding to the next step.

2.

NOTE: Apply a thin soap water film.

Area(1, 2) - Lubricate.

3.

Intermediate Steering Shaft Boot- Inner(1) - Reposition.

4.

When installing the intermediate steering shaft inner boot (1), ensure the inner boot is aligned properly with the intermediate steering shaft outer boot (2).

Do NOT align the intermediate steering shaft inner boot (1) to the bulkhead (3)while installation.

5.

Massage in area (1)on the whole circumference (arrow), the intermediate steering shaft inner boot onto the intermediate steering shaft outer boot.

6. Lift the lip of the intermediate steering shaft inner boot and secure the boot to the intermediate steering shaft pass through.

7.

CAUTION: Fastener Caution

8. Intermediate Steering Shaft Boot Bolt- Inner(1) - Install and tighten[3x] 9 N.m (80 lb in) - Tighten in the sequence shown.

9.

CAUTION: The upper boot must be installed and connected to the lower boot correctly. If not, water could enter the boot and over time, corrode the steering shaft and/or penetrate the input shaft seal of the steering gear. If water enters the steering gear, it may cause loss of power assist.

Inspect for the following conditions:

• Intermediate steering shaft inner boot is NOT flexed, especially in the areas (1, 2).
• NO gap (arrow) between intermediate steering shaft inner boot and intermediate steering shaft outer boot.
• If equipped, intermediate steering shaft outer boot bearing (3) is NOT dislodged.

10. If a condition exists repeat the installation procedure.

11.

Upper Intermediate Steering Shaft(3) & Intermediate Steering Shaft Boot- Upper(1) - Reposition.

12. Upper Intermediate Steering Shaft(3)@Intermediate Steering Shaft - Connect.

Intermediate Steering Shaft Boot Replacement (Outer)

Special Tools

CH-804 Drive Axle Boot Clamp Pliers

Equivalent regional tools:Special Tools

Removal Procedure

1.

Intermediate Steering Shaft Inner Boot(1) - Remove.

2. Remove the front tire and wheel assembly.

3.

Cut the intermediate steering shaft outer boot clamp (1).

DISCARD the clamp.

4.

Slide the intermediate steering shaft outer boot (1) upwards to expose the intermediate steering shaft lower bolt.

5. Intermediate Steering Shaft Lower Bolt(2) - Remove.

6.

Remove the intermediate steering shaft (1) from the vehicle.

7. Remove the intermediate steering shaft outer boot (1) from the vehicle.

Installation Procedure

1.

Position a NEW intermediate steering shaft outer boot clamp (1) onto the intermediate steering shaft outer boot.

2. Position the intermediate steering shaft outer boot (1) on the vehicle.

3.

Position the intermediate steering shaft (1) in the vehicle.

4.

CAUTION: Refer to Fastener Caution.

Intermediate Steering Shaft Lower Bolt(2) - Install and tighten 42 N.m (31 lb ft).

1. Clean the threads of the bolt and mating threads with denatured alcohol or equivalent and allow to dry.
2. Apply thread locking adhesive to the bolt.

5. Slide the intermediate steering shaft outer boot (1) downwards and onto the steering gear.

6. Use the CH-804 pliers (1) to install the NEW intermediate steering shaft outer boot clamp.

7. Install the front tire and wheel assembly.

8.

Intermediate Steering Shaft Inner Boot(1) - Install.

Intermediate Steering Shaft Replacement

Special Tools

CH-804 Drive Axle Boot Clamp Pliers

Equivalent regional tools:Special Tools

Removal Procedure

1.

Intermediate Steering Shaft Inner Boot(1) - Remove.

2. Remove the front tire and wheel assembly.

3.

Cut the intermediate steering shaft outer boot clamp (1).

DISCARD the clamp.

4.

Slide the intermediate steering shaft outer boot (1) upwards to expose the intermediate steering shaft lower bolt.

5. Intermediate Steering Shaft Lower Bolt(2) - Remove.

6.

Remove the intermediate steering shaft (1) from the vehicle.

Installation Procedure

1.

Position a NEW intermediate steering shaft outer boot clamp (1) onto the intermediate steering shaft outer boot.

2.

Position the intermediate steering shaft (1) in the vehicle.

3.

CAUTION: Refer to Fastener Caution.

Intermediate Steering Shaft Lower Bolt(2) - Install and tighten 42 N.m (31 lb ft)

1. Clean the threads of the bolt and mating threads with denatured alcohol or equivalent and allow to dry.
2. Apply thread locking adhesive to the bolt.

4. Slide the intermediate steering shaft outer boot (1) downwards and onto the steering gear.

5. Use the CH-804 pliers (1) to install the NEW intermediate steering shaft outer boot clamp.

6. Install the front tire and wheel assembly.

7.

Intermediate Steering Shaft Inner Boot(1) - Install.

Steering Column Accident Damage Inspection

Inspection Procedure

1. Turn Signal Switch Bracket Replacement - Remove.

CAUTION: Vehicles involved in accidents that result in any of the following kinds of damage or situations, may also have a damaged or misaligned steering column:

• Frame damage
• Major body damage
• Sheet metal damage
• If the steering column has been impacted
• If the supplemental inflatable restraints system was deployed

2. Steering Column Replacement - Remove.

3. Rotate the steering column shaft and verify the shaft turns freely and without interference during the operation.

4. Telescope the steering column in and out and verify there is NO grinding or binding during the operation.

5.

Verify the energy absorbing (E/A) strap retainers (1) are NOT damaged and are fully engaged in the E/A strap.

6. Verify the E/A strap (2) is NOT damaged.

7.

Measure the length (a) of the upper and lower jacket assembly in the fully telescoped position. The length of the upper and lower jacket assembly must NOT be less then 416.4 mm (16.39 in).

8. Measure the length (b) of the upper shaft from the end of the upper jacket to the tip of the shaft. The length of the upper shaft must NOT be less than 62.6 mm (2.46 in).

9. If the steering column does NOT meet the specifications, the steering column is damaged.

DISCARD the damaged steering column and install a NEW steering column.

10. If the steering column meets the specifications, install the steering column.

11. Turn Signal Switch Bracket Replacement - Install.

STEERING COLUMN UPPER TRIM COVER REPLACEMENT

Removal Procedure

1.

Unclip the steering column upper trim cover from the steering column lower trim cover.(1)

2.

Unclip the steering column upper trim cover (1) from the instrument panel upper trim panel.

3. Disconnect the electrical connector.

4.

Unclip the steering column upper trim cover (1) from the instrument cluster assembly.

5. Transfer components as necessary.

Installation Procedure

1.

Install the steering column upper trim cover (1) to the instrument cluster assembly.

2. Connect the electrical connector.

3.

Install the steering column upper trim cover (1) to the instrument panel upper trim panel.

4.

Install the steering column upper trim cover (1) to the steering column lower trim cover.

Steering Column Lower Trim Cover Replacement

Preliminary Procedure

Steering Column Upper Trim Cover Replacement.

1. Steering Column Lower Trim Cover Bolt[3x]

CAUTION: Refer to Fastener Caution.

Procedure

1. Extend the steering column to the fully telescoped position.
2. Remove the lower steering column lower trim cover bolt.
3. Rotate the steering wheel to the left and to the right to remove the upper steering column lower trim cover bolts.

Tighten 2.5 N.m (22 lb in)

2. Steering Column Lower Trim Cover

STEERING COLUMN LOCK CONTROL MODULE REPLACEMENT

WARNING: Before installing the steering column lock control module to the steering column, ensure that no fasteners or debris fall into the column. If fasteners or debris fall into the column, it will cause binding of the steering system, which may result in bodily injury or death.

Preliminary Procedure Unlock the steering column lock control module and remove the steering column along with the steering wheel.

1. Steering Column Lock Control Module Bolt- Rear[2x]
   CAUTION: Fastener Caution
   Tighten
   9.5 N.m (84 lb in)
2. Steering Column Lock Control Module Bolt- Side[2x]
   Tighten
   9.5 N.m (84 lb in)
3. Steering Column Lock Control Module

Procedure

1. Move in the direction of the arrow.
2. Program the steering column lock control module.

TURN SIGNAL SWITCH REPLACEMENT

Preliminary Procedures

1. Steering Column Lower Trim Cover Replacement.

2. Reposition the steering column upper trim cover as necessary.

1. Turn Signal Switch

Procedure

1. Disconnect the electrical connector.
2. Release the retaining tabs and remove the turn signal switch from the turn signal switch bracket.

TURN SIGNAL SWITCH BRACKET REPLACEMENT

Preliminary Procedures

1. Steering Wheel Airbag Coil Replacement.

2. Turn Signal Switch Replacement.

3. Windshield Wiper and Washer Switch Replacement.

1. Turn Signal Switch Bracket

Procedure

1. Release the retaining tabs and remove the turn signal switch bracket from the steering column.
2. Remove and DISCARD

STEERING WHEEL PAD ACCESSORY WIRING HARNESS REPLACEMENT

Preliminary Procedures

1. Remove the left side rear radio control switch.

2. Remove the right side rear radio control switch.

1. Steering Wheel Pad Accessory Wiring Harness

Procedure

1. Disconnect the electrical connectors.
2. Remove the steering wheel pad accessory wiring harness from the steering wheel.

STEERING WHEEL HEAT CONTROL MODULE REPLACEMENT

Preliminary Procedure

Steering Wheel Airbag Replacement
Cruise Control Switch Replacement
Radio Control Switch Replacement - Steering Wheel

1. Steering Wheel Heat Control Module

Procedure

1. Disconnect the electrical connectors.
2. Remove the steering wheel heat control module wiring harness from the steering wheel.
3. Remove the steering wheel heat control module from the steering wheel

STEERING WHEEL REPLACEMENT

Preliminary Procedure

Steering Wheel Airbag Replacement.

1. Steering Wheel Bolt

CAUTION: Refer to Fastener Caution.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners.

Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Procedure

1. Remove and DISCARD the bolt.
2. Apply thread locking adhesive to the NEW bolt.

NOTE:

• Steering wheel bolts installed during manufacturing require higher torque efforts to remove than bolts installed after manufacturing.
• The ONLY acceptable bit for removing and installing the steering wheel bolt is a T50 bit. Do NOT use any other size bit or a worn T50 bit or the bolt recess MAY strip and the bolt may NOT be removable.
• If a power tool is used to remove the steering wheel bolt, the tool must have a torque rating greater than 75 N.m (55 lb ft) and both the power tool and the T50 bit MUST be positioned perpendicular to the bolt recess.

Tighten 45 N.m (33 lb ft)

2. Steering Wheel

Procedure

1. Disconnect the electrical connectors.
2. Install the steering wheel bolt until 2 to 3 threads are engaged.
3. Wiggle the steering wheel until the wheel disengages completely.
4. Steering Wheel Bolt - Remove
5. Steering Wheel - Remove
6. Transfer components as necessary.

STEERING WHEEL SPOKE COVER REPLACEMENT

Preliminary Procedure

Steering Wheel Airbag Replacement.

1. Steering Wheel Spoke Cover Fastener[4x]

CAUTION: Refer to Fastener Caution.

Tighten 1.5 N.m (13 lb in)

2. Steering Wheel Spoke Cover

Procedure

1.  Use a flat bladed plastic tool to remove.
2.  Disconnect the electrical connectors.
3.  Transfer components as necessary.

Steering Column Replacement

Removal Procedure

1. Steering Column Lock Control Module - Unlock.

For Vehicles with automatic transmission:

1. With foot OFF the brake pedal and the shift lever in the PARK position, press the ignition and start switch once. This will place the ignition system in the ACCESSORY mode and unlock the steering column for 5 minutes.
2. Turn the steering wheel to verify the steering column is NOT locked.

NOTE: Steering Column Lock Control Module Fuse

3. F23 Fuse@X51A Fuse Block - Instrument Panel - Remove.
4. With foot OFF the brake pedal and the shift lever in the PARK position, press the ignition and start switch once. This will place the ignition system in the OFF mode and leave the steering column unlocked as long as the steering column lock control module fuse is removed.

For Vehicles with manual transmission:

1. Set the parking brake.
2. With foot OFF the brake pedal and the shift lever in the NEUTRAL position, press the ignition and start switch once. This will place the ignition system in the ACCESSORY mode and unlock the steering column for 5 minutes.
3. Turn the steering wheel to verify the steering column is NOT locked.

NOTE: Steering Column Lock Control Module Fuse

4. F23 Fuse@X51A Fuse Block - Instrument Panel - Remove.
5. With foot OFF the brake pedal and the shift lever in the NEUTRAL position, press the ignition and start switch once. This will place the ignition system in the OFF mode and leave the steering column unlocked as long as the steering column lock control module fuse is removed.

WARNING: SIR Warning.

WARNING: SIR Inflator Module Handling and Storage Warning.

2. Disable the SIR system.

3.

Steering Wheel - Remove.

4.

Steering Column Upper Trim Cover(1) - Remove.

5.

Steering Column Lower Trim Cover(1) - Remove.

6.

Steering Wheel Airbag Coil(1) - Remove.

7.

Turn Signal Switch Bracket(1) - Remove and DISCARD.

8.

Instrument Panel Knee Bolster(1) - Remove.

9.

Floor Front Air Outlet Duct - Left Side(1) - Remove.

10.

CAUTION: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

• The steering column
• The intermediate shaft(s)
• The steering gear

After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has become un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

NOTE: Place match marks on the steering column shaft and the upper intermediate steering shaft to aid in installation.

Upper Intermediate Steering Shaft(1)@Steering Column - Separate.

11. Disconnect the steering column electrical connectors as necessary.

12.

Steering Column Nut(1) - Remove and DISCARD[4x].

13.

CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on the end could collapse the steering shaft or loosen the plastic injections, which maintain column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the columns collapsible design. Do NOT hammer on the end of the shaft, because hammering could loosen the plastic injections, which maintain column rigidity. If you need to remove the steering wheel, refer to the Steering Wheel Replacement procedure in this section.

Steering Column(1) - Remove.

14.

Steering Column Lock Control Module(3) - Remove.

15. If replacing the steering column, copy the match marks from the OLD steering column to the NEW steering column.

Installation Procedure

1.

WARNING: Before installing the steering column lock control module to the steering column, ensure that no fasteners or debris fall into the column. If fasteners or debris fall into the column, it will cause binding of the steering system, which may result in bodily injury or death.

Steering Column Lock Control Module(3) - Install.

2.

Steering Column(1) - Install.

3.

Steering Column Nut(1) - Install, but do NOT tighten[4x] - Use NEW nuts.

4.

CAUTION: Fastener Caution

Steering Column Nut(1) - Tighten in sequence[4x] 22 N.m (16 lb ft).

5. Connect the steering column electrical connectors.

6.

Upper Intermediate Steering Shaft(1)@Steering Column - Install.

7.

Floor Front Air Outlet Duct - Left Side(1) - Install.

8.

Instrument Panel Knee Bolster(1) - Install.

9.

Turn Signal Switch Bracket(1) - Install NEW.

10.

Steering Wheel Airbag Coil(1) - Install.

11.

Steering Column Lower Trim Cover(1) - Install.

12.

Steering Column Upper Trim Cover(1) - Install.

13.

Steering Wheel - Install.

14. Enable the SIR System.

NOTE: Steering Column Lock Control Module Fuse.

15. F23 Fuse@X51A Fuse Block - Instrument Panel - Install.

16. Center the steering angle sensor.

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