Cockpit Module Page 5–1
Page 5–1
Section 5
Cockpit Module
ATTENTION
Before performing any Service Operation or other procedure described in this Section, refer to Section 00
WARNINGS, CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property
damage.
The Structure of the MY 2004 WK Series body
shell has been developed using complex
design and development techniques. In
addition to meeting all required standards, the
vehicle body is also a critical part of the
overall safety systems. It is therefore
imperative the repair procedures described
here are adhered to during all vehicle body
repairs.
1 General Information............................................................................................................................... 2
Cockpit Module Page 5–2
Page 5–2
1 General Information
This Section contains the cockpit module body structure repair information for the MY 2004 WK Series Vehicles.
The cockpit module is a production line sub-assembly consisting of the instrument panel, heater & A/C module assembly,
steering column, pedal assembly, wiring, etc. mounted to the dash panel assembly.
During production, the cockpit module is fitted to the vehicle in one operation. It is lowered through the windshield
opening and the dash panel assembly is fitted into a channel known as the glue-track, which is part of the front floor
panel extension and hinge pillar inner panel assembly.
The glue track is filled with a special silicone adhesive prior to the cockpit module being installed. The dash panel
assembly aligns with several dimples and four bolts secure it to the vehicle: two through the hinge pillar and two in the
plenum area. Once the adhesive cures, the dash panel assembly becomes an integral part of the body structure.
The dash panel assembly is clearly visible from within the engine compartment. It is the gloss-black body panel forming
the plenum chamber below the windshield and continuing to the floor panel. The glue-track can be seen where the dash
panel assembly joins the hinge pillars and floor.
The silicone adhesive is a specific type for this application and is suited for the high temperatures generated within the
engine compartment. It has excellent bonding, sealing and longevity characteristics. This technique has been in use for
many years.
The components of the cockpit module, e.g. instrument panel, steering column, heater & A/C module assembly, etc. can
be serviced in the normal manner. The dash panel assembly can also be serviced, however due to the fact it is ‘glued-in’,
the correct procedures must be followed.
For replacement and repair of the dash panel assembly refer to Section 1E, Cockpit Module in the MY 2004 WK Series
Service Information.