Light Scratches; Large Scratches And Abrasions; Front Body Components; Dashboard Removal - Pioneer 1200 Maintenance Service Manual

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BODY AND TRIM

LIGHT SCRATCHES

Ajax cleanser applied dry and hand-rubbed will rapidly smooth moderate scratches. Use a soft polishing
compound to restore gloss.
Scratches (up to 10 mils; the equivalent thickness of an average business card) can be removed by light
sanding. Start with wet silicone carbide abrasive paper (320 grit or finer). Use progressively finer grits (i.e.
400, 600, 800) to reduce sanding marks. Use Ajax cleanser (or equivalent) for final smoothing. A "Micro
Mesh" acrylic polishing kit with abrasive papers from 1800 to 8000 grit will provide the best final finish.
Restore gloss with soft polishing compound, or Club Car's Vehicle Care Kit (CCI P/N AM10021). It is not the
intent of any of these processes to 'fill-in' the material removed due to light scratches but rather to blend the
finish of the surrounding area and the scratch together.

LARGE SCRATCHES AND ABRASIONS

Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and
body repair shop with experience repairing ABS/DR acrylic bodies.

FRONT BODY COMPONENTS

See General Warning, Section 1, Page 1-1.

DASHBOARD REMOVAL

1. Make sure the key switch is OFF and the Forward/Reverse handle is in NEUTRAL. Remove the key.
Chock the wheels.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-2.
3. Remove the dash panel.
3.1. Loosen the seven Tuflok
3.2. Remove Tuflok screws from dash panel shown in Detail B.
3.3. Pull forward on top of the dash panel to access back of the panel.
4. Disconnect the wiring from components mounted in the dash panel.
5. Remove five caps (1) from top of dashboard (2) (Figure 4-2, Page 4-5).
6. Remove screws (3) and special plastic washers (4) from top of dashboard (2) using a Torx #T-30 driver.
7. Remove five screws (5) from underside of dashboard and pull dashboard away from front body (6).
8. Remove the steering wheel. See Steering Wheel Removal, Section 7, Page 7-1.
9. Remove dashboard from vehicle.

DASHBOARD INSTALLATION

1. Reverse the dashboard removal process.
2. Tighten screws (5) to 11 in-lb (1.2 N·m) (Figure 4-2, Page 4-5).
3. Tighten Torx-head screws (3) with plastic washers (4) to 45 in-lb (5.1 N·m).
4. Install five caps (1).
5. Install the dash panel and connect wiring to panel components.
6. Install steering wheel. See Steering Wheel Installation, Section 7, Page 7-3.
Page 4-2 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
®
screws shown in Detail A (Figure 4-1, Page 4-3).
Front Body Components