Instrument Panel, Gauges and Warning Indicators: Service and Repair

The content of this article reflects the changes identified in TSB 06-08-49-001

Bulletin No.06-08-49-001

Date:January 04, 2006

SERVICE MANUAL UPDATE

Subject:

Revised Instrument Panel Tie Bar Replacement

Models: 2005-2006 Chevrolet Cobalt 2005-2006
Pontiac Pursuit (Canada Only)



Instrument Panel Tie Bar Replacement

Removal Procedure

1. Disable the SIR System Zones 3 and 5.
2. Remove the Instrument Panel Retainer.
3. Lower the Steering Column and position out of the way.






4. Remove the nuts securing the HVAC module to the body.






5. It the vehicle is equipped with a manual transmission, remove the nut (1) securing the clutch pedal to the Tie Bar.
6. Push the Bolt (2) inward just enough to clear the Tie Bar Bracket. DO NOT remove the bolt completely.






7. Remove the nuts (2) securing the clutch pedal bracket and Tie Bar Assembly to the cowl.
8. Remove the nuts (1) securing the Brake Pedal Bracket to the cowl.






9. Remove the nuts securing the Tie Bar Assembly to the HVAC Module.






10. Remove the bolts securing the Tie Bar Assembly to the body.
11. Note the routing of the Instrument Panel wiring harness prior to removing the tie Bar Assembly to ensure proper reinstallation.
12. Lift upward on the tie bar assembly enough that the studs clear the HVAC module assembly.
13. With the aid of an assistant remove the Tie Bar from the vehicle.


Installation Procedure

1. With the aid of an assistant, install the Tie Bar Assembly to the vehicle.






2. Route the Instrument Panel wiring harness around the Tie Bar Assembly as noted in the removal procedure.
3. Install the bolts securing the Tie Bar Assembly to the body.

Tighten

Tighten the bolts to 25 Nm (18 lb ft).







4. Install the nuts securing the Tie Bar Assembly to the HVAC Module.

Tighten

Tighten the bolts to 10 Nm (89 lb in).






5. Install the nuts (2) securing the clutch pedal bracket and Tie Bar Assembly to the cowl.

Tighten

Tighten the nuts to 10 Nm (89 lb in).

6. Install the nuts (1) securing the Brake Pedal Bracket to the cowl.

Tighten

Tighten the nuts to 17 Nm (12 lb ft).






7. It the vehicle is equipped with a manual transmission, install the nut (1) securing the clutch pedal to the Tie Bar.

Tighten

Tighten the nut to 10 Nm (89 lb in).






8. Install the nuts securing the HVAC module to the body.

Tighten

Tighten the nut to 10 Nm (89 lb in).


9. Install the Steering Column.
10. Install the Instrument Panel Retainer.
11. Enable the SIR System Zones 3 and 5. Refer to SIR Disabling and Enabling and SIR Disabling and Enabling.