GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Tracker - 2WD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Instrument Panel Assembly Replacement

Removal Procedure

    Object Number: 477532 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Disable the SIR system. Refer to SIR Disabling and Enabling and SIR Disabling and Enabling in SIR.
  3. Remove the instrument panel (I/P) compartment. Refer to Instrument Panel Compartment Replacement .
  4. Remove the following components from the I/P assembly (2):
    5. 4.1. The 3 screws (3)
    4.2. The I/P compartment trim plate (1)

    Object Number: 477544 Size: SH
  5. Remove the inflatable restraint I/P module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  6. Remove the front floor console. Refer to Front Floor Console Replacement .
  7. Remove the ashtray lamp bulb. Refer to Ashtray Lamp Bulb Replacement in Lighting Systems.
  8. Remove the radio, if equipped. Refer to Radio Replacement in Entertainment.
  9. Remove the radio opening cover, if equipped. Refer to Radio Opening Cover Replacement in Instrument Panel Gages and Console.
  10. Remove the cigar lighter. Refer to Cigar Lighter Housing Replacement .
  11. Remove the instrument cluster. Refer to Instrument Cluster Replacement .
  12. Using a taped flat-bladed tool, gently pry the 2 I/P accessory trim plate switch hole covers (2) located below the hazard and defogger switches from the I/P assembly
  13. Using a taped flat-bladed tool, gently pry the hazard warning switch (1) from the I/P assembly.

    14. Object Number: 477543 Size: SH
  14. Disconnect the hazard warning switch electrical connector (2).
  15. Remove the switch (1) from the vehicle.

    16. Object Number: 477545 Size: SH
  16. Using a taped flat-bladed tool, gently pry the rear window defogger switch (1) from the I/P assembly, if equipped.

    17. Object Number: 477547 Size: SH
  17. Disconnect the rear window defogger switch electrical connector (2), if equipped.
  18. Remove the switch (1) from the vehicle, if equipped.
  19. Remove the heater control unit. Refer to Heater and Air Conditioning Control Replacement in HVAC Systems - Manual.
  20. Remove the I/P lamp dimmer control.
  21. Remove the cruise control switch, if equipped. Refer to Cruise Control Switch Replacement in Cruise Control.
  22. Remove the outside remote control rearview mirror switch, if equipped. Refer to Power Mirror Switch Replacement .
  23. Remove the rear window wiper/washer switch, if equipped. Refer to Rear Window Wiper and Washer Switch Replacement in Wipers/Washer Systems.
  24. Using a taped flat-bladed tool, gently pry and remove the I/P accessory trim plate switch hole covers located next to the switches at the left of the I/P assembly.

    25. Object Number: 477550 Size: SH
  25. Remove the following components from the vehicle:
    26. 25.1. The 8 bolts (1 and 4)
    25.2. The I/P drivers knee bolster panels (2 and 3)
  26. Remove the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.

    27. Object Number: 477551 Size: SH
  27. Remove the screw (2) that retains the hood latch release handle (1) to the I/P assembly (3).
  28. Position the hood latch release handle (1) aside in order to gain the necessary clearance to remove the I/P assembly (3).
  29. Gently pry loose and remove the windshield side garnish moldings.
  30. Disconnect the 6 I/P wiring harness electrical connectors from the junction block.
  31. Disconnect the radio antenna cable lead from the extension cable in the junction block area.
  32. Remove the connector position assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) electrical connector.
  33. Disconnect the SDM electrical connector.
  34. Remove the bolt that retains the I/P wiring harness ground wire. The bolt and the ground wire are located to the left front of the SDM.
  35. Remove the ambient light sensor. Refer to Daytime Running Lamp (DRL) Ambient Light Sensor Replacement in Lighting Systems.

    36. Object Number: 477555 Size: SH
  36. Remove the 2 bolts (3, 6) that retain each side of the I/P assembly (2).
  37. Fold back the floor panel carpet around the center of the I/P assembly (2) in order to access the 2 center I/P mounting bolts (4) at each side.
  38. Remove the 2 center I/P mounting bolts (4) that retain each side of the I/P assembly (2).

    39. Object Number: 477554 Size: SH
  39. Remove the bolt (2) that is located in the steering column area that retains the I/P assembly (1).

    40. Object Number: 477552 Size: SH
  40. Remove the left upper I/P bolt trim cover (1) from the I/P assembly (2).

    41. Object Number: 477553 Size: SH
  41. Remove the right upper I/P bolt trim cover (1) from the I/P assembly (2).

    42. Object Number: 477555 Size: SH
  42. Remove the 2 upper I/P mounting bolts (1) that retain the I/P assembly (2).
  43. Remove the I/P assembly (2) from the vehicle.

    44. Object Number: 477520 Size: SH
  44. Remove the following components from the I/P assembly:
    45. 44.1. The screw (2)
    44.2. The air distribution center duct (1)

    Object Number: 477521 Size: SH
  45. Remove the following components from the I/P assembly:
    46. 45.1. The 4 screws (1)
    45.2. The windshield defroster outlet duct (2)
    45.3. The heater duct

    Object Number: 477526 Size: SH
  46. Remove the screw (3) from the left side of the rear of the I/P assembly (1) that retains the I/P wiring harness (2).

    47. Object Number: 477525 Size: SH
  47. Remove the 2 screws (1) from the center of the rear of the I/P assembly (3) that retain the I/P wiring harness (2).

    48. Object Number: 477526 Size: SH
  48. Remove the screw (3) from the right side of the rear of the I/P assembly (1) that retains the I/P wiring harness (2).

    49. Object Number: 477522 Size: SH
  49. Release the wiring harness retainers and remove the I/P wiring harness (2) from the I/P reinforcement (1).

    50. Object Number: 477527 Size: SH
  50. Remove the following components from the I/P assembly:
    51. 50.1. The 10 screws
    50.2. The 4 bolts
    50.3. The I/P reinforcement
    50.4. The left windshield defroster nozzle air deflector (3)
    50.5. The 3 screws
    50.6. The right windshield defroster nozzle air deflector
    50.7. The 2 screws
    50.8. The I/P compartment door reinforcement (1)

    Object Number: 477529 Size: SH
  51. Remove the following components from the I/P assembly (3):
    52. 51.1. The 4 screws (2)
    51.2. The I/P passengers knee bolster panel (1)

    Object Number: 477527 Size: SH
  52. Remove the left vent outlet deflector (2) from the I/P assembly.

    53. Object Number: 477528 Size: SH
  53. Remove the following components from the I/P assembly (1):
    54. 53.1. The 3 screws
    53.2. The center I/P bracket (2)

    Object Number: 477531 Size: SH
  54. Remove the following components from the I/P assembly (3):
    55. 54.1. The 2 screws (2)
    54.2. The left I/P bracket (1)

Installation Procedure

    Object Number: 477531 Size: SH
  1. Install the left I/P bracket (1) to the I/P assembly (3). Secure the bracket with the 2 screws (2).

    2. Object Number: 477528 Size: SH
  2. Install the center I/P bracket (2) to the I/P assembly (1). Secure the bracket with the 3 screws.

    3. Object Number: 477527 Size: SH
  3. Install the left vent outlet deflector (2) to the I/P assembly.

    4. Object Number: 477529 Size: SH
  4. Install the I/P passengers knee bolster panel (1) to the I/P assembly (3). Secure the panel with the 4 screws (2).

    5. Object Number: 477527 Size: SH
  5. Install the I/P compartment door reinforcement (1) to the I/P assembly. Secure the reinforcement with 2 screws.
  6. Install the right windshield defroster nozzle air deflector to the I/P assembly. Secure the air deflector with the 3 screws.
  7. Install the left windshield defroster nozzle air deflector (3) to the I/P assembly.

    8. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the I/P reinforcement to the I/P assembly. Secure the reinforcement with the following:
    9. 8.1. The 10 screws
    8.2. The 4 bolts

    Tighten
    Tighten the I/P reinforcement bolts to 23 N·m (17 lb ft).


    Object Number: 477522 Size: SH
  9. Install the I/P wiring harness (2) to the I/P reinforcement (1). Secure the harness with the plastic retainers.

    10. Object Number: 477526 Size: SH
  10. Install the screw (3) to the left side of the rear of the I/P assembly (1) that retains the I/P wiring harness (2).

    11. Object Number: 477525 Size: SH
  11. Install the 2 screws (1) to the center of the rear of the I/P assembly (3) that retain the I/P wiring harness (2).

    12. Object Number: 477526 Size: SH
  12. Install the screw (3) to the right side of the rear of the I/P assembly (1) that retains the I/P wiring harness (2).

    13. Object Number: 477521 Size: SH
  13. Install the heater duct to the I/P assembly.
  14. Install the windshield defroster outlet duct (2) to the I/P assembly. Secure the outlet duct with the 4 screws (1).

    15. Object Number: 477520 Size: SH
  15. Install the air distribution center duct (1) to the I/P assembly. Secure the center duct with the screw (2).

    16. Object Number: 477555 Size: SH
  16. Install the I/P assembly (2) to the vehicle. Secure the I/P with the 2 upper I/P mounting bolts (1). Do not tighten completely at this time.

    17. Object Number: 477554 Size: SH
  17. Install the bolt (2) that is located in the steering column area that retains the I/P assembly (1). Do not tighten completely at this time.

    18. Object Number: 477555 Size: SH
  18. Install the 2 center I/P mounting bolts (4) at each side that retain the I/P assembly (2). Do not tighten completely at this time.
  19. Install the 2 bolts (3, 6) at each side that retain the I/P assembly (2).

    20. Tighten
    Tighten all of the I/P mounting bolts to 23 N·m (17 lb ft).

  20. Reposition the floor panel carpet around the center of the I/P assembly (2).
  21. Install the left upper I/P bolt trim cover to the I/P assembly.
  22. Install the right upper I/P bolt trim cover to the I/P assembly.
  23. Install the ambient light sensor. Refer to Daytime Running Lamp (DRL) Ambient Light Sensor Replacement in Lighting Systems.

    24. Object Number: 477551 Size: SH
  24. Install the bolt that retains the I/P wiring harness ground wire. The bolt and the ground wire are located to the left front of the inflatable restraint sensing and diagnostic module (SDM).
  25. Connect the SDM electrical connector. Secure the connector with the CPA.
  26. Connect the radio antenna cable lead to the extension cable in the junction block area.
  27. Connect the 6 I/P wiring harness electrical connectors to the junction block.
  28. Install the windshield side garnish moldings.
  29. Install the hood latch release handle (1) to the I/P assembly (3). Secure the handle with the screw (2).

    30. Object Number: 477550 Size: SH
  30. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
  31. Install the I/P drivers knee bolster panels (2 and 3) to the vehicle. Secure the bolster panels with the 8 bolts (1 and 4).

    32. Object Number: 477547 Size: SH
  32. Install the I/P lamp dimmer control.
  33. Install the outside remote control rearview mirror switch, if equipped. Refer to Power Mirror Switch Replacement .
  34. Install the cruise control switch, if equipped. Refer to Cruise Control Switch Replacement in Cruise Control.
  35. Install the rear window wiper/washer switch, if equipped. Refer to Rear Window Wiper and Washer Switch Replacement in Wipers/Washer Systems.
  36. Install the I/P accessory trim plate switch hole covers that are located next to the switches at the left of the I/P assembly.
  37. Install the heater control unit. Refer to Heater and Air Conditioning Control Replacement in HVAC Systems - Manual.
  38. Connect the rear window defogger switch electrical connector (2), if equipped.
  39. Install the rear window defogger switch (1) to the I/P assembly, if equipped. Ensure that the retaining tabs are completely engaged.

    40. Object Number: 477543 Size: SH
  40. Connect the hazard warning switch electrical connector (2).
  41. Install the hazard warning switch (1) to the I/P assembly. Ensure that the retaining tabs are completely engaged.
  42. Install the 2 I/P accessory trim plate switch hole covers that are located below the hazard and defogger switches to the I/P assembly.
  43. Install the instrument cluster. Refer to Instrument Cluster Replacement .
  44. Install the cigar lighter. Refer to Cigar Lighter Housing Replacement .
  45. Install the radio, if removed. Refer to Radio Replacement in Entertainment.
  46. Install the radio opening cover, if removed. Refer to Radio Opening Cover Replacement in Instrument Panel, Gages, and Console.
  47. Install the ashtray lamp bulb. Refer to Ashtray Lamp Bulb Replacement in Lighting Systems.
  48. Install the front floor console. Refer to Front Floor Console Replacement .
  49. Install the inflatable restraint I/P module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.

    50. Object Number: 477532 Size: SH
  50. Install the I/P compartment trim plate (1) to the I/P assembly (2). Secure the trim plate with the 3 screws (3).
  51. Install the I/P compartment. Refer to Instrument Panel Compartment Replacement .
  52. Enable the SIR System. Refer to SIR Disabling and Enabling and SIR Disabling and Enabling in SIR.
  53. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.