GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 GTO 🢒 Body 🢒 Collision Repair 🢒 Dash Panel Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

    Important: Before beginning the repair, refer to Metal Panel Bonding in Collision Repair for proper adhesive applicator preparations and general information.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.

    6. Object Number: 1380599 Size: SH

    Important: The dash panel bolts (1) must be replaced when performing this procedure.

  6. Remove the dash panel bolt (1) from each hinge pillar.

    7. Object Number: 1380600 Size: SH

    Important: The dash panel screws (1) must be replaced when performing this procedure.

  7. From within the plenum chamber, remove the dash panel screw (1) from each side.

    8. Object Number: 1380602 Size: SH
  8. Remove the 2 screws (2) attaching the body earth ground strap (1) and remove.
  9. Remove the identification plates from the dash panel.
  10. Transfer the identification plates onto the new dash panel.

    11. Object Number: 1380606 Size: SH
  11. Remove the retainer (2) attaching the lower dash panel outer insulator (1) to the engine compartment side of the dash panel.

    12. Object Number: 1380603 Size: SH
  12. Transfer the dash panel upper insulator (1) from the existing dash panel to the new dash panel.

    13. Object Number: 1380608 Size: SH
  13. The dash panel lower deadener (1) cannot be transferred to the new dash panel; a new deadener will be required.

    14. Object Number: 1380612 Size: SH
  14. Remove the 2 retainers (2) which secure the dash panel lower insulator inner and transfer the dash panel lower insulator inner (1) from the existing dash panel.

    15. Object Number: 1380613 Size: SH
  15. Transfer the plug (3), if fitted, spacer (1) and plug (2).

    16. Object Number: 1380614 Size: SH
  16. Using a cutting tool, cut the dash panel assembly (A) approximately 50 mm (2 in) above the glue track.
  17. Remove the dash panel assembly section.
  18. Cut the section of remaining panel to enable removal of the main wiring harness.

    19. Object Number: 1380617 Size: SH
  19. Drill a hole in the flange above the transmission tunnel, and attach a chain block and a clevis.
  20. Apply and maintain a light tension to the remaining part of the dash panel assembly.
  21. Either cut the adhesive with a hot knife or heat the adhesive using a heat gun and pull the panel from the glue track.
  22. Clean the excess adhesive from the glue track using a hot knife or a heat gun.

Installation Procedure

    Important: 

       â€¢ The service part comes as an assembly that includes the plenum lower panel. If the repair does not require the plenum, remove the plenum before you install the dash panel.
       â€¢ Before painting the vehicle, apply masking tape to prevent paint entering the glue track.

  1. The vehicle should be painted before installation of the dash panel assembly. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  2. Temporarily install the new dash panel assembly prior to applying the adhesive to check for correct fit.

    3. Important: The vehicle surface should be finished and the paint fully dry before installation.

  3. Prepare all mating surfaces as necessary.

    4. Important: 

       â€¢ Installation is best performed with the aid of an assistant.
       â€¢ The adhesive has a 40-50 minute working time. Do not allow the dash panel to totally cure off the vehicle, as proper alignment of the dash panel to the vehicle will be difficult.

  4. Apply metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5), or equivalent, to the glue track from the lowest points to prevent air bubbles forming in the adhesive. Completely fill the channel in a continuous bead.
  5. Apply a patch of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5), or equivalent, approximately 50 mm (2 in) diameter to the base of the windshield pillar.
  6. Hold the dash panel assembly in position slightly above the glue track.

    7. Object Number: 1380621 Size: SH
  7. With the aid of an assistant, pass the main wiring harness (3) through the opening in the dash panel.
  8. Install the dash panel outer opening cover (1) onto the dash panel assembly.
  9. Affix the dash panel side insulator (3) over the cover and fold over the back of the panel as shown (4).

    10. Object Number: 1380624 Size: SH
  10. Lower the dash panel assembly (1), ensuring the flange seats correctly in the glue track.

    11. Important: Check to ensure that the section around the main wiring harness hole is correctly installed.

  11. Push the panel firmly into the glue track channel until the mounting bolt holes align.

    12. Object Number: 1380599 Size: SH
  12. Install 2 new dash panel bolts (1) through the hinge pillar and hand tighten.

    13. Object Number: 1380600 Size: SH
  13. Install 2 new screws (1) to the plenum chamber and hand tighten.

    14. Notice: Refer to Fastener Notice in the Preface section.

  14. Inspect the flanges to make sure they are correctly seated.

    15. Tighten
    Tighten the dash panel bolts to 40 N·m (30 lb ft).

  15. Continue to tighten the plenum chamber screws.

    16. Tighten
    Tighten the plenum chamber screws to 25 N·m (18 lb ft).


    Object Number: 1380627 Size: SH
  16. Wipe any excess adhesive from the plenum drain hole (1), each side, and the glue track areas (2).
  17. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  18. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.

    19. Object Number: 1380602 Size: SH
  19. Install the body earth ground strap (1) and the 2 screws (2).

    20. Tighten
    Tighten the ground strap screws to 3 N·m (27 lb in).

  20. Install all of the related panels and components.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  22. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.