Service Procedure
Service ProcedureUsing the Global Warranty Management System, determine the build date of the vehicle.
- If the vehicle was built between 3/2/09 through 1/17/10, refer to First Design Magnesium Beam Service Repair.
- If the vehicle was built between 1/18/10 through 5/12/10, refer to Second Design Magnesium Beam Service Repair.
First Design Magnesium Beam Service Repair
Passenger Side Lower Magnesium Beam Cut Procedure
1. Remove the instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Right Side (Left Hand Drive) in SI.
2. Remove instrument panel compartment from the vehicle. Refer to Instrument Panel Compartment Replacement (Left Hand Side) in SI. Destroy the instrument panel compartment assembly (door and storage bin) and retain for the required 15 days after claim payment.
3. Remove the instrument panel side trim panel assembly. Refer to Instrument Panel Side Trim Panel Assembly Replacement in SI.
4. Cover the work area with a plastic covering or drop cloth. The work area includes the front passenger side of the vehicle. The plastic covering or drop cloth will protect the interior of the vehicle from debris.
5. Remove the screw on the outboard instrument panel plastic retainer.
6. Remove the screw on the lower outboard instrument panel plastic retainer.
7. Remove the screw on upper end of the OnStar module.
8. Remove the three screws (1) from the instrument panel plastic retainer.
9. Separate the instrument panel plastic retainer (2) from the magnesium beam (1).
1. Carefully insert a piece of wood (or equivalent) that is 165 mm (6.5 in) in length between the instrument panel plastic retainer (1) and the frame (2) as shown in the illustration.
2. Insert a screwdriver, or equivalent, between the front center section of the magnesium beam and the instrument panel plastic retainer as shown to hold the instrument panel plastic retainer away from the magnesium beam.
3. Using a pen, mark a cut line on the inboard side of the end cinch nuts (1). Refer to the illustration. The cut lines should be as close to the cinch nuts as possible.
4. Ensure that the instrument panel plastic retainer (4) is separated from the magnesium beam (3).
Caution
Do NOT damage the end cinch nuts (1) while cutting the center section of the magnesium beam. The end cinch nuts are required to secure the instrument panel compartment assembly.
5. Cut and remove the center portion of the lower magnesium beam (3) using a cut-off wheel, Dremel tool, or equivalent. A picture after the removal of the center portion of the lower magnesium beam is shown above.
10. Pull up on the instrument panel plastic retainer to locate the instrument panel plastic retainer screw holes to the end cinch nuts on the magnesium beam.
11. Install the two end screws into the cinch nuts on the magnesium beam.
12. Install the screw on the upper end of OnStar module.
13. Install the screw on the lower outboard instrument panel plastic retainer.
14. Install the screw on the outboard instrument panel plastic retainer.
Outboard Passenger Side Lower Magnesium Beam Cut Completed in Step 9.5
Right Hand Side Instrument Panel Plastic Retainer Cut Procedure
Left portion of illustration shows the underside of the instrument panel plastic retainer. Right portion of the illustration shows the front and topside of the instrument panel plastic retainer.
Note
The cut line should follow the edge of the outboard passenger side magnesium beam cut made in Step 9.5. Refer to Outboard Passenger Side Lower Magnesium Beam Cut Completed in the Step 9.5 illustration. Callout 2 shows the pre-drill of the outboard passenger side cut. End the cut line 1-2 mm (3/64-5/64 in) before the front face (5) surface edge (3) of the instrument panel plastic retainer.
15. Using a pen, mark a cut line (1) on the underside of the instrument panel plastic retainer along the outboard passenger side magnesium beam cut.
16. Drill a hole at the end point of the cut line using a 4.74 mm (3/16 in) drill bit. Drill the hole from the top of the instrument panel plastic retainer as shown in illustration.
17. Cut the underside of the instrument panel plastic retainer to the hole made in step 16.
Instrument Panel Insulator Screw Hole Cut Procedure
18. Modify the two instrument panel insulator screw holes (1). Refer to illustration.
1. Using a pen, mark an 11 o'clock to 2 o'clock notch into the two screw holes. The notches should be slightly larger than the head of the screws.
2. Using a box cutter (or equivalent tool) cut out the notched area of the screw holes.
19. Remove the plastic cover or drop cloth from the passenger side of vehicle. Clean the remaining debris from the interior.
Note
Ensure that the instrument panel insulator is retained by pressing on the insulator from the top side (through the instrument panel compartment) while ensuring that there is no fore/aft movement of the panel that could later result in a rattle or undesired disengagement of the panel to the aft attachments.
20. Install the instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Right Side (Left Hand Drive) in SI.
21. Install the new instrument panel compartment. Refer to Instrument Panel Compartment Replacement (Left Hand Side) in SI.
22. Install the instrument panel side trim panel assembly. Refer to Instrument Panel Side Trim Panel Assembly Replacement in SI.
Second Design Magnesium Beam Service Repair
1. Remove the instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Right Side (Left Hand Drive) in SI.
2. Remove the instrument panel compartment from the vehicle. Refer to Instrument Panel Compartment Replacement (Left Hand Side) in SI. Destroy the instrument panel compartment assembly (door and storage bin) and retain for the required 15 days after claim payment.
3. Cover the work area with a plastic covering or drop cloth. The work area includes the front passenger side of the vehicle. The plastic covering or drop cloth will protect the interior of the vehicle from debris.
4. Remove the three screws (1) from the instrument panel plastic retainer.
5. Separate the instrument panel plastic retainer from the magnesium beam.
Callouts (1), (2) & (3) show cut out portions of the second design magnesium beam
6. Follow the production outboard passenger side cutout (3). Refer to the illustration. End the cut line 1-2 mm (3/64-5/64 in) before the front face (5) surface edge (3) of the instrument panel plastic retainer. Remove the three instrument panel plastic retainer screws to view the production outboard passenger side cutout (3). Re-install the screws after viewing the cutout.
Right Hand Side Instrument Panel Plastic Retainer Cut Procedure
Left portion of illustration shows the underside of the instrument panel plastic retainer. Right portion of the illustration shows the front and topside of the instrument panel plastic retainer.
7. Drill a hole (2) at the end point of the cut line (1) using a 4.74 mm (3/16 in) drill bit. Drill the hole from the top of the instrument panel plastic retainer (4) as shown in illustration.
8. Cut the underside of the magnesium beam (1) retainer to the hole (2) made in Step 7.
9. Modify the two instrument panel insulator screw holes (1). Refer to the illustration.
1. Using a pen, mark an 11 o'clock to 2 o'clock notch into the two screw holes. The notches should be slightly larger than the head of the screws.
2. Using a box cutter (or equivalent tool), cut out the notched area of the screw holes.
10. Remove the plastic cover or drop cloth from the passenger side of the vehicle. Clean the remaining debris from the interior.
Note
Ensure that the instrument panel insulator is retained by pressing on the insulator from the top side (through the instrument panel compartment) while ensuring there is no fore/aft movement of the panel that could later result in a rattle or undesired disengagement of the panel to the aft attachments.
11. Install the instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Right Side (Left Hand Drive) in SI.
12. Install the new instrument panel compartment. Refer to Instrument Panel Compartment Replacement (Left Hand Side) in SI.