Instrument Panel Assembly Replacement...Remove the I/P upper trim panel. Refer to Instrument Panel...
Transcript of Instrument Panel Assembly Replacement...Remove the I/P upper trim panel. Refer to Instrument Panel...
2005 Pontiac G6 : Body > Interior > Instrument Panel, Gages, And Console > Repair Instructions > Instrument Panel
Assembly Replacement
Instrument Panel Assembly Replacement
INSTRUMENT PANEL ASSEMBLY REPLACEMENT
Tools Required
J 39400-A (Image 1) Halogen Leak Detector
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative
Cable Disconnection and Connection in Engine Electrical.
2. Drain the coolant. Refer to Cooling System Draining and Filling
(Refer To List 1) in Engine Cooling.
3. Remove the inlet heater hose at the heater core. Refer to Heater Inlet
Hose Replacement (Refer To List 2) in Heating, Ventilation, and Air
Conditioning.
4. Remove the outlet heater hose at the heater core. Refer to Heater
Outlet Hose Replacement (Refer To List 3) in Heating, Ventilation,
and Air Conditioning.
5. Recover the refrigerant. Refer to Refrigerant Recovery and
Recharging in Heating, Ventilation, and Air Conditioning.
6. Remove the suction hose at the thermostatic expansion valve (TXV).
Refer to Thermal Expansion Valve Replacement in Heating,
Ventilation, and Air Conditioning.
7. Remove the liquid line at the TXV. Refer to Thermal Expansion
Valve Replacement in Heating, Ventilation, and Air Conditioning.
8. Remove and discard the sealing washers.
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NOTE Important: Plug the heater core pipes and the TXV opening to prevent coolant or polyalkylene glycol (PAG) oil from leaking into the interior.
Plug all A/C components immediately to prevent system
contamination.
9. Disconnect the HVAC module to front of dash plate bolts.
10. Remove the right console trim panel. Refer to Front Floor Console
Side Trim Panel Replacement - Right Side .
11. Remove the left console trim panel. Refer to Front Floor Console
Side Trim Panel Replacement - Left Side .
12. Remove the console. Refer to Console Replacement .
13. Remove the left closeout panel. Refer to Instrument Panel Insulator
Panel Replacement - Left Side .
14. Remove both instrument panel (I/P) outer trim panels. Refer to
Instrument Panel Outer Trim Cover Replacement .
Listen
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15. Remove the I/P to the body wire harness and antenna LH connectors.
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16. Remove the I/P to the wire harness RH connectors.
17. Remove the knee bolster. Refer to Knee Bolster Replacement .
18. Remove the steering column to the I/P wire harness connector. Refer
to Steering Column Replacement (Refer To List 4) in Steering
Wheel and Column.
Click to Enlarge
19. Remove the crush bracket to the front of dash plate nuts.
20. Remove the upper steering column shroud from the lower shroud.
Refer to Steering Column Trim Covers Replacement in Steering
Wheel and Column.
21. Remove the stalk switches and the SIR coil connectors. Refer to Turn
Signal Multifunction Switch Replacement in Steering Wheel and
Column.
22. Position the steering wheel in full forward telescoping position.
23. Position the front seat in the full rearward position.
24. Remove the steering column mounting bolts. Refer to Steering
Column Replacement (Refer To List 4) in Steering Wheel and
Column.
25. Lower the steering column to the floor.
26. Remove the brake pedal assembly. Refer to Brake Pedal Assembly
Replacement in Hydraulic Brakes.
27. Remove the body control module (BCM). Refer to Body Control
Module Replacement in Computer/Integrating Systems.
Listen
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28. Remove the center support bracket floor bolts. Refer to Instrument
Panel Center Support Bracket Replacement .
29. Remove the shifter assembly. Refer to Transmission Control
Replacement (Refer To List 5) in Automatic Transaxle -
4T40-E/4T45-E.
30. Remove both windshield pillar garnish moldings. Refer to Windshield
Pillar Garnish Molding Replacement (Refer To List 6) in Interior
Trim.
31. Remove the I/P upper trim panel. Refer to Instrument Panel Upper
Trim Panel Replacement .
Click to Enlarge
32. Remove the I/P body LH bolts.
Listen
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33. Remove the I/P body RH bolts.
34. Remove the right hand floor heater duct at the center floor heater
duct. Refer to Rear Floor Air Outlet Duct Replacement - Right Side
in Heating, Ventilation, and Air Conditioning.
35. Remove the left hand floor heater duct at the center floor heater duct.
Refer to Rear Floor Air Outlet Duct Replacement - Left Side in
Heating, Ventilation, and Air Conditioning.
36. Remove the I/P assembly.
Listen
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37. Remove and discard HVAC module drain seal and dash seal.
Installation Procedure
1. Install new HVAC module drain seal and dash seal.
Listen
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2. Install the I/P assembly.
3. Install the left hand floor heater duct at the center floor heater duct.
Refer to Rear Floor Air Outlet Duct Replacement - Left Side in
Heating, Ventilation, and Air Conditioning.
4. Install the right hand floor heater duct at the center floor heater duct.
Refer to Rear Floor Air Outlet Duct Replacement - Right Side in
Heating, Ventilation, and Air Conditioning.
NOTE Notice: Refer to Fastener Notice (Refer To List 7) in the Preface section.
Click to Enlarge
5. Install the I/P body RH bolts.
Tighten
Tighten the bolts to 26 N·m (19 lb ft).
Listen
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6. Install the I/P body LH bolts.
Tighten
Tighten the bolts to 26 N·m (19 lb ft).
7. Install the I/P upper trim panel. Refer to Instrument Panel Upper
Trim Panel Replacement .
8. Install both windshield pillar garnish moldings. Refer to Windshield
Pillar Garnish Molding Replacement (Refer To List 6) in Interior
Trim.
9. Install the shifter assembly. Refer to Transmission Control
Replacement (Refer To List 5) in Automatic Transaxle -
4T40-E/4T45-E.
10. Install the center support bracket floor bolts. Refer to Instrument
Panel Center Support Bracket Replacement .
Tighten
Tighten the bolts to 10 N·m (89 lb in).
11. Install the BCM. Refer to Body Control Module Replacement in
Computer/Integrating Systems.
12. Install the brake pedal assembly. Refer to Brake Pedal Assembly
Replacement in Hydraulic Brakes.
13. Install the steering column assembly. Refer to Steering Column
Replacement (Refer To List 4) in Steering Wheel and Column.
Listen
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14. Install the stalk switches and the SIR coil connectors. Refer to Turn
Signal Multifunction Switch Replacement in Steering Wheel and
Column.
15. Install the upper steering column shroud from the lower shroud. Refer
to Steering Column Trim Covers Replacement in Steering Wheel
and Column.
Click to Enlarge
16. Install the crush bracket to the front of dash plate nuts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
17. Install the steering column to the I/P wire harness connector. Refer to
Steering Column Replacement (Refer To List 4) in Steering Wheel
and Column.
18. Install the knee bolster. Refer to Knee Bolster Replacement .
Listen
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19. Install the I/P to the body wire harness RH connectors.
Listen
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20. Install the I/P to the body wire harness and antenna LH connectors.
21. Install both I/P outer trim panels. Refer to Instrument Panel Outer
Trim Cover Replacement .
22. Install the left closeout panel. Refer to Instrument Panel Insulator
Panel Replacement - Left Side .
23. Install the console. Refer to Console Replacement .
24. Install the left console trim panel Refer to Front Floor Console Side
Trim Panel Replacement - Left Side .
25. Install the right console trim panel. Refer to Front Floor Console
Side Trim Panel Replacement - Right Side .
Click to Enlarge
26. Install the HVAC module to the MOD plate bolts.
Tighten
Tighten the bolts to 4 N·m (35 lb in).
27. Unplug A/C components.
28. Install new sealing washers. Refer to Sealing Washer Replacement
in Heating, Ventilation, and Air Conditioning.
29. Install the liquid line at the TXV. Refer to Thermal Expansion Valve
Replacement in Heating, Ventilation, and Air Conditioning.
Listen
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30. Install the suction hose at the TXV. Refer to Thermal Expansion
Valve Replacement in Heating, Ventilation, and Air Conditioning.
31. Evacuate and charge the refrigerant system. Refer to Refrigerant
Recovery and Recharging in Heating, Ventilation, and Air
Conditioning.
32. Leak test the fittings using the J 39400-A (Image 1) .
33. Install the outlet heater hose at the heater core. Refer to Heater
Outlet Hose Replacement (Refer To List 3) in Heating, Ventilation,
and Air Conditioning.
34. Install the inlet heater hose at the heater core. Refer to Heater Inlet
Hose Replacement (Refer To List 2) in Heating, Ventilation, and Air
Conditioning.
35. Fill the coolant. Refer to Cooling System Draining and Filling
(Refer To List 1) in Engine Cooling.
36. Connect the negative battery cable. Refer to Battery Negative Cable
Disconnection and Connection in Engine Electrical.
REFERED IMAGES LIST:
REFER TO LIST:
(Image 1) J 39400-A
List 1
◾ Engine / Engine Cooling / Repair Instructions / Cooling System
Draining And Filling
◾ Engine / Engine Cooling / Repair Instructions / Cooling System
Draining And Filling (LX9, LZ9 Static Fill)
◾ Engine / Engine Cooling / Repair Instructions / Cooling System
Draining And Filling (Ge 47716 Fill)
◾ Engine / Engine Cooling / Repair Instructions / Cooling System
Draining And Filling (LE5 Static Fill)
Listen
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List 2
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Inlet Hose Replacement (LX9)
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Inlet Hose Replacement (LX9, LZ9)
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Inlet Hose Replacement (LE5)
List 3
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Outlet Hose Replacement (LX9)
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Outlet Hose Replacement (LX9, LZ9)
◾ HVAC / Heating, Ventilation And Air Conditioning / Repair
Instructions / Heater Outlet Hose Replacement (LE5)
List 4
◾ Steering / Steering Wheel And Column / Repair Instructions /
Steering Column Replacement
◾ Steering / Steering Wheel And Column / Repair Instructions /
Steering Column Replacement (Electronic)
◾ Steering / Steering Wheel And Column / Repair Instructions /
Steering Column Replacement (Hydraulic)
List 5
◾ Transmission/Transaxle / Automatic Transaxle - 4T40-E/4T45-E /
Repair Instructions / Transmission Control Replacement
◾ Transmission/Transaxle / Automatic Transaxle - 4T45-E / Repair
Instructions / Transmission Control Replacement
◾ Transmission/Transaxle / Automatic Transaxle - 4T65-E / Repair
Instructions / Transmission Control Replacement
List 6
◾ Body / Interior Trim / Repair Instructions / Windshield Pillar
Garnish Molding Replacement
◾ Body / Interior Trim / Repair Instructions / Windshield Pillar
Garnish Molding Replacement (Sedan)
◾ Body / Interior Trim / Repair Instructions / Windshield Pillar
Garnish Molding Replacement (Convertible)
List 7
◾ Preface / Cautions And Notices / Introduction / Fastener Notice
◾ Unsorted / Fastener Notice
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