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 .

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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.

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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



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 .

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32. Remove the I/P body LH bolts.

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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.

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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.

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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


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


NOTE Notice: Refer to Fastener Notice (Refer To List 7) in the Preface section.

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5. Install the I/P body RH bolts.

Tighten

Tighten the bolts to 26 N·m (19 lb ft).

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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



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.

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16. Install the crush bracket to the front of dash plate nuts.

Tighten


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 .

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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


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



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


Draining And Filling (LX9, LZ9 Static Fill)


Draining And Filling (Ge 47716 Fill)


Draining And Filling (LE5 Static Fill)

Listen



List 2

◾ HVAC / Heating, Ventilation And Air Conditioning / Repair

Instructions / Heater Inlet Hose Replacement (LX9)


Instructions / Heater Inlet Hose Replacement (LX9, LZ9)


Instructions / Heater Inlet Hose Replacement (LE5)

List 3


Instructions / Heater Outlet Hose Replacement (LX9)


Instructions / Heater Outlet Hose Replacement (LX9, LZ9)


Instructions / Heater Outlet Hose Replacement (LE5)

List 4

◾ Steering / Steering Wheel And Column / Repair Instructions /

Steering Column Replacement


Steering Column Replacement (Electronic)


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


Garnish Molding Replacement (Sedan)


Garnish Molding Replacement (Convertible)

List 7

◾ Preface / Cautions And Notices / Introduction / Fastener Notice

◾ Unsorted / Fastener Notice

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instrument panel assembly replacement...remove the i/p upper trim panel. refer to instrument panel...

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