Operation CHARM: Car repair manuals for everyone.
Home >> Chevrolet >> 2009 >> Malibu L4-2.4L >> Repair and Diagnosis >> Body and Frame >> Interior Moulding / Trim >> Dashboard / Instrument Panel >> Service and Repair >> Instrument Panel Assembly Removal

Instrument Panel Assembly Removal




Instrument Panel Assembly Removal

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LZ4, LY7, and LE5) (Service and Repair)Battery Negative Cable Disconnection and Connection (LAT) (Service and Repair).
2. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill-LE5, LAT) (Service and Repair)Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
3. Remove the inlet heater hose at the heater core. Refer to Heater Inlet Hose Replacement (LAT Pump to Engine) ()Heater Inlet Hose Replacement (LAT Pump to Heater Core) ()Heater Inlet Hose Replacement (LY7) (Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (LE5) (Heater Inlet Hose Replacement).
4. Remove the outlet heater hose at the heater core. Refer to Heater Outlet Hose Replacement (LY7) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LAT) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LE5) (Heater Outlet Hose Replacement).
5. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
6. Remove the suction hose at the thermostatic expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Air Conditioning Evaporator Thermal Expansion Valve Replacement).
7. Remove the liquid line at the thermostatic expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Air Conditioning Evaporator Thermal Expansion Valve Replacement).
8. Remove and discard the sealing washers.





Note: 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. Remove the HVAC module to front of dash plate bolts (1).
10. Remove the front floor console. Refer to Front Floor Console Replacement (Service and Repair).
11. Remove the body control module. Refer to Body Control Module Replacement (Service and Repair).
12. Remove the right and left instrument panel insulator panels. Refer to Instrument Panel Insulator Replacement - Right Side (Service and Repair) and Instrument Panel Insulator Replacement - Left Side (Service and Repair).
13. Remove both the right and left instrument panel outer trim panels. Refer to Instrument Panel Outer Trim Cover Replacement (Service and Repair).




14. Disconnect the instrument panel to the body wire harness and antenna connectors on the left side of the instrument panel (1).




15. Disconnect the instrument panel to the wire harness connectors on the right side of the instrument panel (1).
16. Remove the drivers knee bolster panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair).
17. Remove the steering column assembly. Refer to Steering Column Replacement (Hydraulic Power Steering) (Steering Column Replacement (Hydraulic Power Steering))Steering Column Replacement (Electronic Power Steering) (Steering Column Replacement (Electronic Power Steering)).




18. Remove the crush bracket to the front of dash plate nuts (1).
19. Position the front seat in the full rearward position.
20. Remove the brake pedal assembly. Refer to Brake Pedal Assembly Replacement (Service and Repair).
21. Remove the shifter assembly. Refer to Transmission Control Replacement (Transmission Control Replacement).
22. Remove both right and left windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (Service and Repair).
23. Remove the instrument panel upper trim panel. Refer to Instrument Panel Upper Trim Panel Replacement (Service and Repair).




24. Remove the left side instrument panel to body bolts (1).




25. Remove the right side instrument panel to body bolts (1).
26. Remove the right hand floor heater duct at the center floor heater duct. Refer to Floor Rear Air Outlet Duct Replacement - Right Side (Floor Rear Air Outlet Duct Replacement - Right Side).
27. Remove the left hand floor heater duct at the center floor heater duct. Refer to Floor Rear Air Outlet Duct Replacement - Left Side (Floor Rear Air Outlet Duct Replacement - Left Side).
28. Remove the instrument panel assembly from the vehicle.




29. Remove and discard HVAC module drain seal (2) thermostatic expansion valve and dash seal (1).

Installation Procedure

1. Install a new HVAC module drain seal (2) and dash seal (1).




2. Install the instrument panel assembly into the vehicle.
3. Install the left hand floor heater duct at the center floor heater duct. Refer to Floor Rear Air Outlet Duct Replacement - Left Side (Floor Rear Air Outlet Duct Replacement - Left Side).
4. Install the right hand floor heater duct at the center floor heater duct. Refer to Floor Rear Air Outlet Duct Replacement - Right Side (Floor Rear Air Outlet Duct Replacement - Right Side).





Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the right hand side instrument panel to body bolts (1) and tighten to 26 Nm (19 lb ft).




6. Install the left hand side instrument panel to body bolts (1) and tighten to 26 Nm (19 lb ft).
7. Install the instrument panel upper trim panel. Refer to Instrument Panel Upper Trim Panel Replacement (Service and Repair).
8. Install both the right and left windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (Service and Repair).
9. Install the shifter assembly. Refer to Transmission Control Replacement (Transmission Control Replacement).
10. Install the brake pedal assembly. Refer to Brake Pedal Assembly Replacement (Service and Repair).




11. Install the crush bracket to the front of dash plate nuts (1). Tighten the bolts to 10 Nm (89 lb in).
12. Install the steering column assembly. Refer to Steering Column Replacement (Hydraulic Power Steering) (Steering Column Replacement (Hydraulic Power Steering))Steering Column Replacement (Electronic Power Steering) (Steering Column Replacement (Electronic Power Steering)).
13. Install the drivers knee bolster panel. Refer to Driver Knee Bolster Panel Replacement (Service and Repair).




14. Connect the instrument panel to body wire harness connectors on the right side of the instrument panel (1).




15. Connect the instrument panel to body wire harness connectors and antennas on the left side of the instrument panel (1).
16. Install the right and left instrument panel outer trim panels. Refer to Instrument Panel Outer Trim Cover Replacement (Service and Repair).
17. Install the right and left instrument panel insulator panels. Refer to Instrument Panel Insulator Replacement - Right Side (Service and Repair) and Instrument Panel Insulator Replacement - Left Side (Service and Repair).
18. Install the BCM. Refer to Body Control Module Replacement (Service and Repair).
19. Install the front floor console. Refer to Front Floor Console Replacement (Service and Repair).




20. Install the HVAC module to the MOD plate bolts (1) and tighten to 4 Nm (35 lb in).
21. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (Sealing Washer Replacement).
22. Install the liquid line at the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Air Conditioning Evaporator Thermal Expansion Valve Replacement).
23. Install the suction hose at the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Air Conditioning Evaporator Thermal Expansion Valve Replacement).
24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
25. Leak test the fittings using the J 39400-A .
26. Repair any leaks found.
27. Install the outlet heater hose at the heater core. Refer to Heater Outlet Hose Replacement (LY7) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LAT) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LE5) (Heater Outlet Hose Replacement).
28. Install the inlet heater hose at the heater core. Refer to Heater Inlet Hose Replacement (LAT Pump to Engine) ()Heater Inlet Hose Replacement (LAT Pump to Heater Core) ()Heater Inlet Hose Replacement (LY7) (Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (LE5) (Heater Inlet Hose Replacement).
29. Fill the coolant. Refer to Cooling System Draining and Filling (Static Fill-LE5, LAT) (Service and Repair)Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LZ4, LY7, and LE5) (Service and Repair)Battery Negative Cable Disconnection and Connection (LAT) (Service and Repair).

pro multis · About Operation CHARM