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Home >> Chevrolet >> 2004 >> Malibu Maxx >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panel System Displays, Gauges And Console >> Repair Instructions >> Instrument Panel (I/P) Assembly Replacement >> Removal Procedure

Removal Procedure

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Drain the coolant. Refer to Draining and Filling Cooling System (L61) and Draining and Filling Cooling System (LX9) in Engine Cooling.
  3. Remove the inlet heater hose at the heater core. Refer to Heater Hose Replacement - Inlet (L61) and Heater Hose Replacement - Inlet (LX9) in Heating, Ventilation, and Air Conditioning.
  4. Remove the outlet heater hose at the heater core. Refer to Heater Hose Replacement - Outlet (L61) and Heater Hose Replacement - Outlet (LX9) 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.
    9. Fig 1: View Of HVAC Module To Front Of Dash Plate Bolts
    GM1206844Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Plug the heater core pipes and the TXV opening to prevent coolant or 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 Console Trim Panel Replacement - Right .
  11. Remove the left console trim panel. Refer to Console Trim Panel Replacement - Left .
  12. Remove the console. Refer to Console Replacement .
  13. Remove the left closeout panel. Refer to Closeout/Insulator Panel Replacement - Left .
  14. Remove both instrument panel (I/P) outer trim panels. Refer to Instrument Panel (I/P) Outer Trim Cover Replacement .
    15. Fig 2: View Of I/P To Body Wire Harness And Antenna LH Connectors
    GM1206847Courtesy of GENERAL MOTORS CORP.
  15. Remove the I/P to the body wire harness and antenna LH connectors.
    16. Fig 3: View Of I/P To Wire Harness RH Connectors
    GM1206859Courtesy of GENERAL MOTORS CORP.
  16. Remove the I/P to the wire harness RH connectors.
  17. Remove the knee bolster. Refer to Knee Bolster Replacement .
  18. Remove the accelerator pedal. Refer to Accelerator Controls Pedal Replacement in Engine Controls - 2.2L.
  19. Remove the steering column to the I/P wire harness connector. Refer toSteering Column Replacement in Steering Wheel and Column.
    20. Fig 4: View Of Crush Bracket To Front Of Dash Plate Nuts
    GM1206851Courtesy of GENERAL MOTORS CORP.
  20. Remove the crush bracket to the front of dash plate nuts.
  21. Remove the upper steering column shroud from the lower shroud. Refer toSteering Column Trim Covers Replacement in Steering Wheel and Column.
  22. Remove the stalk switches and the SIR coil connectors. Refer to Multifunction, Turn Signal Switch Replacement in Steering Wheel and Column.
  23. Position the steering wheel in full forward telescoping position.
  24. Position the front seat in the full rearward position.
  25. Remove the steering column mounting bolts. Refer to Steering Column Replacement in Steering Wheel and Column.
  26. Lower the steering column to the floor.
  27. Remove the brake pedal assembly. Refer to Brake Pedal Assembly Replacement in Hydraulic Brakes.
  28. Remove the body control module (BCM). Refer to Body Control Module Replacement in Computer/Integrating Systems.
  29. Remove the center support bracket floor bolts. Refer to Bracket Replacement - Instrument Panel (I/P) Center Support .
  30. Remove the shifter assembly. Refer to Floor Shift Control Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  31. Remove both windshield pillar garnish moldings. Refer to Garnish Molding Replacement - Windshield Pillar in Interior Trim.
  32. Remove the I/P upper trim panel. Refer to Trim Panel Replacement - Instrument Panel (I/P) Upper .
    33. Fig 5: View Of I/P Body LH Bolts
    GM1206866Courtesy of GENERAL MOTORS CORP.
  33. Remove the I/P body LH bolts.
    34. Fig 6: View Of I/P Body RH Bolts
    GM1206861Courtesy of GENERAL MOTORS CORP.
  34. Remove the I/P body RH bolts.
  35. Remove the right hand floor heater duct at the center floor heater duct. Refer to Air Outlet Duct Replacement - Rear Floor, RH in Heating, Ventilation, and Air Conditioning.
  36. Remove the left hand floor heater duct at the center floor heater duct. Refer to Air Outlet Duct Replacement - Rear Floor, LH in Heating, Ventilation, and Air Conditioning.
  37. Remove the I/P assembly.
    38. Fig 7: View Of And Discard HVAC Module Drain Seal And Dash Seal
    GM1339693Courtesy of GENERAL MOTORS CORP.
  38. Remove and discard HVAC module drain seal and dash seal.
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