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Home >> Chevrolet >> 2004 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Electrical >> Instrument Panel System Displays, Gauges And Console >> Repair Instructions >> Instrument Panel (I/P) Assembly Replacement >> Removal Procedure

Removal Procedure

  1. Remove the driver seat. Refer to Seat Replacement - Bucket in Seats.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  2. Disconnect the battery cables, and remove the battery. Refer to Battery Replacement in Engine Electrical.
  3. Remove the bolt that retains the underhood fuse block to the bulkhead.
    CAUTION: Refer to SIR Caution in Cautions and Notices.
  4. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 , SIR Disabling and Enabling Zone 5 , and SIR Disabling and Enabling Zone 7 in SIR.
  5. Remove the face-plate (2) from the outer housing of the junction block (1).
    Fig 1: Location Of Junction Block
    GM708155Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the engine harness electrical connector (3) from the junction block (1).
    Fig 2: Identifying Engine Harness Electrical Connector
    GM708091Courtesy of GENERAL MOTORS CORP.
  7. Separate the outer housing of the junction block (2) from the bulkhead.
  8. Remove the 2 studs that retain the junction block (1) to the bulkhead.
    Fig 3: View Of Junction Block Retaining Studs
    GM708169Courtesy of GENERAL MOTORS CORP.
  9. Remove the junction block from the bulkhead.
  10. Remove the nut (2) that retains the I/P harness grounding strap (1) to the body.
    Fig 4: Identifying I/P Harness Grounding Strap Nut
    GM710378Courtesy of GENERAL MOTORS CORP.
  11. Remove the I/P harness grounding strap (1) from the body.
  12. Disconnect the I/P from the forward lamp harness connector (3).
  13. Disconnect the forward lamp from the I/P harness connector (4).
  14. Disconnect the engine from the forward lamp harness connector (5).
  15. Disconnect the electrical connector of the cruise control module (3).
    Fig 5: Locating Cruise Control Module Electrical Connector
    GM710372Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the electrical connector of the windshield wiper motor (2).
  17. Disconnect the electrical connector of the rear lamp wiring harness (1).
  18. Remove the power steering fluid reservoir from the bulkhead. Refer to Remote Power Steering Fluid Reservoir Replacement in Power Steering System.
  19. Remove the cruise control module from the bulkhead. Refer to Cruise Control Module Replacement in Cruise Control.
  20. Note the routing of the I/P wire harness on the engine side of the bulkhead. Remove the I/P wire harness from the bulkhead.
  21. Remove the I/P extension from the vehicle. Refer to Instrument Panel (I/P) Extension Replacement .
  22. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  23. Remove the driver knee bolsters and the passenger knee bolsters. Refer to Knee Bolster Replacement - Right  or to Knee Bolster Replacement - Left .
  24. Remove cowl trim panels on the right side, and on the left side. Refer to Trim Panel Replacement - Cowl Side in Interior Trim.
  25. Remove the left carpet retainers and the right carpet retainers. Refer to Carpet Retainer Replacement in Interior Trim.
  26. Remove the HVAC floor vent cover that is located behind the driver seat. Refer to Air Outlet Replacement - Rear Floor in Heating, Ventilation and Air Conditioning.
  27. Lift the carpet in order to access the sensing and diagnostic module (SDM).
  28. Disconnect the CPA and the electrical connector from the SDM.
  29. Feed the seat wire harnesses through the access hole in the carpet.
  30. Remove the SDM and the seat wire harness from the trough along the left door sill.
  31. Disconnect the 16-way I/P from the body harness (2).
    Fig 6: Locating 16-way I/P Connector
    GM710076Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the 10-way I/P from the body harness (1).
  33. Disconnect the ground strap harness for the left door (1).
    Fig 7: View Of Left Door Ground Strap Harness
    GM710085Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the left door harness connector (2).
  35. Disconnect the door jamb switch connector on the left (3).
  36. Release the harness straps in order to remove the harnesses from the trough.
  37. Disconnect the headliner connector (2) from the I/P junction block.
    Fig 8: Identifying Headliner Electrical Connector
    GM710381Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the heater jumper connector (3) from the body harness.
  39. Remove the electrical connector of the power seat harness from the I/P junction block.
  40. Disconnect the electrical connector of the park brake from the park brake switch. Refer to Park Brake Warning Lamp Switch Replacement in Park Brake.
  41. Remove the black 6-way connector from the I/P junction block.
  42. Disconnect the roof console harness connector (1) from the I/P junction block.
    Fig 9: Locating Roof Console Harness Electrical Connector
    GM710385Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the trailer wiring harness connector (2) from the I/P junction block.
  44. Disconnect the orange 3-way in-line connector (1).
    Fig 10: Identifying Orange 3-Way In-Line Electrical Connector
    GM754028Courtesy of GENERAL MOTORS CORP.
  45. Disconnect the black 5-way in-line connector.
  46. Disconnect the brake switch electrical connector.
    Fig 11: Locating Brake Switch Electrical Connector
    GM161582Courtesy of GENERAL MOTORS CORP.
  47. Remove the air outlet duct from the left lap. Refer to Air Outlet Duct Replacement - Left Lap in Heating, Ventilation and Air Conditioning.
  48. Remove the bolts that are retaining the left lap bracket of the air outlet duct to the I/P carrier.
    Fig 12: View Of Left Lap Bracket Of The Air Outlet Duct Retaining Bolts
    GM317075Courtesy of GENERAL MOTORS CORP.
  49. Remove the left lap bracket of the air outlet duct from the I/P carrier.
  50. Disconnect the steering column harness connector by loosening the bolt (2) in the center of the connector.
    Fig 13: Locating Steering Column Harness Electrical Connector Bolts
    GM708497Courtesy of GENERAL MOTORS CORP.
  51. Remove the steering column from the I/P carrier. Refer to Steering Column Replacement in Steering Wheel and Column.
  52. In order to remove the right I/P harness, disconnect the following components:
    • The door lock relay harness (1)
    • The door jamb switch harness (3)
    • The ground terminal harness (4)
    • The I/P door connector harness (5)
    • The liftgate connector harness (6)
    • The I/P harness fastener (7)
    Fig 14: Identifying Right I/P Harness Components
    GM708316Courtesy of GENERAL MOTORS CORP.
  53. Remove the fastener that is retaining the door lock control module (2) to the body.
  54. Disconnect the HVAC actuator, which is a black 5-way connector, and the vacuum lines.
    Fig 15: View Of HVAC Actuator
    GM835183Courtesy of GENERAL MOTORS CORP.
  55. Remove the I/P cluster trim panel. Refer to Trim Panel Replacement - Instrument Panel (I/P) Cluster .
  56. Remove the radio. Refer to Radio Replacement in Entertainment.
  57. Remove the HVAC control assembly. Refer to HVAC Control Assembly Replacement in Heating, Ventilation and Air Conditioning.
  58. Remove the I/P cluster. Refer to Instrument Panel Cluster (IPC) Replacement .
  59. Locate the instrument panel that retains the I/P carrier to the carrier support brackets. Remove the 2 bolts on the left sides and on the right sides of the instrument panel.
  60. Slide the instrument panel away from the bulkhead.
  61. Lift the instrument panel up and off the pivot points.
    Fig 16: Expanded View Of I/P Carrier Instrument Panel Retaining Bolts
    GM317065Courtesy of GENERAL MOTORS CORP.
  62. Remove the I/P assembly from the vehicle.
  63. Place the I/P assembly on a clean surface.
  64. In order to remove the I/P from the I/P carrier, perform the remaining steps of this procedure. Remove the center defogger grille from the I/P.
  65. Remove the ambient light sensor of the daytime running lamps (DRL). Refer to Daytime Running Lamps (DRL) Ambient Light Sensor Replacement in Lighting Systems.
  66. Remove the HVAC ducts from the I/P assembly. Refer to Air Outlet Duct Replacement - Left Floor in Heating, Ventilation and Air Conditioning.
  67. From the rear of the I/P, remove the 5 screws that retain the top of the I/P to the carrier.
    Fig 17: View Of Top I/P Carrier Retaining Screws
    GM317099Courtesy of GENERAL MOTORS CORP.
  68. Remove the body control module (BCM) from the BCM bracket. Refer to Body Control Module Replacement in Body Control System.
  69. Remove the remote keyless entry receiver from the I/P substrate. Refer to Remote Control Door Lock Receiver Replacement in Keyless Entry.
  70. From the front of the I/P, remove the 6 screws that retain the bottom of the I/P to the carrier.
    Fig 18: Expanded View Of I/P Carrier Instrument Panel Retaining Bolts
    GM317065Courtesy of GENERAL MOTORS CORP.
  71. Remove the I/P inflatable restraint. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  72. Remove the I/P from the I/P carrier.
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