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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 › Installation Procedure

Installation Procedure

  1. Install the I/P inflatable restraint. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  2. At the front of the I/P, install the 6 screws that retain the bottom of the I/P to the carrier.
    Fig 1: Expanded View Of I/P Carrier Instrument Panel Retaining Bolts
    GM317065Courtesy of GENERAL MOTORS CORP.
  3. Install the remote keyless entry receiver to the I/P substrate. Refer to Remote Control Door Lock Receiver Replacement in Keyless Entry.
  4. Install the body control module (BCM) to the BCM bracket. Refer to Body Control Module Replacement in Body Control System.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. At the rear of the I/P, install the 5 screws that retain the top of the I/P to the carrier.

    Tighten:  Tighten the bolt to 20 N.m (15 lb ft).

    Fig 2: View Of Top I/P Carrier Retaining Screws
    GM317099Courtesy of GENERAL MOTORS CORP.
  6. Install the HVAC ducts to the I/P assembly. Refer to Air Outlet Duct Replacement - Left Floor in Heating, Ventilation and Air Conditioning.
  7. Install the ambient light sensor of the daytime running lamps (DRL). Refer to Daytime Running Lamps (DRL) Ambient Light Sensor Replacement in Lighting Systems.
  8. Install the center defogger grille to the I/P. This completes the installation of the I/P to the I/P carrier.
  9. Install the I/P assembly to the vehicle.
  10. Lift the instrument panel up and off the pivot points.
  11. Slide the instrument panel away to the bulkhead.
  12. Locate the instrument panel that retains the I/P carrier to the carrier support brackets. Install the 2 bolts on the left sides, and on the right sides of the instrument panel.

    Tighten:  Tighten the bolt to 45 N.m (33 lb ft).

    Fig 3: Expanded View Of I/P Carrier Instrument Panel Retaining Bolts
    GM317065Courtesy of GENERAL MOTORS CORP.
  13. Install the I/P cluster. Refer to Instrument Panel Cluster (IPC) Replacement .
  14. Install the HVAC control assembly. Refer to HVAC Control Assembly Replacement in Heating, Ventilation and Air Conditioning.
  15. Install the radio. Refer to Radio Replacement in Entertainment.
  16. Install the I/P cluster trim panel. Refer to Trim Panel Replacement - Instrument Panel (I/P) Cluster .
  17. Connect the HVAC actuator, which is a black 5-way connector, and the vacuum lines.
    Fig 4: View Of HVAC Actuator
    GM835183Courtesy of GENERAL MOTORS CORP.
  18. Install the fastener that is retaining the door lock control module to the body.
  19. In order to install the right I/P harness, connect 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 5: Identifying Right I/P Harness Components
    GM708316Courtesy of GENERAL MOTORS CORP.
  20. Install the steering column to the I/P carrier. Refer to Steering Column Replacement in Steering Wheel and Column.
  21. Connect the steering column harness connector by loosening the bolt (2) in the center of the connector.
    Fig 6: Locating Steering Column Harness Electrical Connector Bolts
    GM708497Courtesy of GENERAL MOTORS CORP.
  22. Install the left lap bracket of the air outlet duct to the I/P carrier.
  23. Install the bolts that are retaining the left lap bracket of the air outlet duct to the I/P carrier.
    Fig 7: View Of Left Lap Bracket Of The Air Outlet Duct Retaining Bolts
    GM317075Courtesy of GENERAL MOTORS CORP.
  24. Install the air outlet duct to the left lap. Refer to Air Outlet Duct Replacement - Left Lap in Heating, Ventilation and Air Conditioning.
  25. Connect the brake switch electrical connector.
    26. Fig 8: Locating Brake Switch Electrical Connector
    GM161582Courtesy of GENERAL MOTORS CORP.
  26. Connect the black 5-way in-line connector.
  27. Connect the orange 3-way in-line connector (1).
    Fig 9: Identifying Orange 3-Way In-Line Electrical Connector
    GM754028Courtesy of GENERAL MOTORS CORP.
  28. Connect the trailer wiring harness connector to the I/P junction block.
  29. Connect the roof console harness connector (1) to the I/P junction block.
    Fig 10: Locating Roof Console Harness Electrical Connector
    GM710385Courtesy of GENERAL MOTORS CORP.
  30. Install the black 6-way connector to the I/P junction block.
  31. Connect the electrical connector of the park brake to the park brake switch. Refer to Park Brake Warning Lamp Switch Replacement in Park Brake.
  32. Install the electrical connector of the power seat harness to the I/P junction block.
  33. Connect the heater jumper connector to the body harness.
  34. Connect the headliner connector (2) to the I/P junction block.
    Fig 11: Identifying Headliner Electrical Connector
    GM710381Courtesy of GENERAL MOTORS CORP.
  35. Release the harness straps in order to install the harnesses to the trough.
  36. Connect the door jamb switch connector on the left (3).
  37. Connect the left door harness connector (2).
  38. Connect the ground strap harness for the left door (1).
    Fig 12: View Of Left Door Ground Strap Harness
    GM710085Courtesy of GENERAL MOTORS CORP.
  39. Connect the 10-way I/P to the body harness (1).
  40. Connect the 16-way I/P to the body harness (2).
    Fig 13: Locating 16-way I/P Connector
    GM710076Courtesy of GENERAL MOTORS CORP.
  41. Install the SDM and the seat wire harness to the trough along the left door sill.
  42. Feed the seat wire harnesses through the access hole in the carpet.
  43. Connect the CPA and the electrical connector to the SDM.
  44. Lift the carpet in order to access the sensing and diagnostic module (SDM).
  45. Install 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.
  46. Install the left carpet retainers and the right carpet retainers. Refer to Carpet Retainer Replacement in Interior Trim.
  47. Install cowl trim panels on the right side, and on the left side. Refer to Trim Panel Replacement - Cowl Side in Interior Trim.
  48. Install the driver knee bolsters and the passenger knee bolsters. Refer to Knee Bolster Replacement - Right  or to Knee Bolster Replacement - Left .
  49. Install the engine cover to the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  50. Install the I/P extension to the vehicle. Refer to Instrument Panel (I/P) Extension Replacement .
  51. Note the routing of the I/P wire harness on the engine side of the bulkhead. Install the I/P wire harness to the bulkhead.
  52. Install the cruise control module to the bulkhead. Refer to Cruise Control Module Replacement in Cruise Control.
  53. Install the power steering fluid reservoir to the bulkhead. Refer to Remote Power Steering Fluid Reservoir Replacement in Power Steering System.
  54. Connect the electrical connector of the rear lamp wiring harness (1).
  55. Connect the electrical connector of the windshield wiper motor (2).
  56. Connect the electrical connector of the cruise control module (3).
    Fig 14: Locating Cruise Control Module Electrical Connector
    GM710372Courtesy of GENERAL MOTORS CORP.
  57. Connect the engine to the forward lamp harness connector.
  58. Connect the forward lamp to the I/P harness connector.
  59. Connect the I/P to the forward lamp harness connector (3).
  60. Install the I/P harness grounding strap (1) to the body.
  61. Install the nut (2) that retains the I/P harness grounding strap (1) to the body.

    Tighten:  Tighten the bolt to 2 N.m (18 lb in).

    Fig 15: Identifying I/P Harness Grounding Strap Nut
    GM710378Courtesy of GENERAL MOTORS CORP.
  62. Install the junction block to the bulkhead.
  63. Install the 2 studs that retain the junction block (1) to the bulkhead.

    Tighten:  Tighten the bolt to 2 N.m (18 lb in).

    Fig 16: View Of Junction Block Retaining Studs
    GM708169Courtesy of GENERAL MOTORS CORP.
  64. Separate the outer housing of the junction block to the bulkhead.
  65. Connect the engine harness electrical connector (3) to the junction block (1).
    Fig 17: Identifying Engine Harness Electrical Connector
    GM708091Courtesy of GENERAL MOTORS CORP.
  66. Install the face-plate (2) to the outer housing of the junction block (1).
    Fig 18: Location Of Junction Block
    GM708155Courtesy of GENERAL MOTORS CORP.
  67. Enable 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.
  68. Install the bolt that retains the underhood fuse block to the bulkhead.

    Tighten:  Tighten the bolt to 2 N.m (18 lb in).

  69. Connect the battery cables, and install the battery. Refer to Battery Replacement in Engine Electrical.
  70. Install the driver seat. Refer to Seat Replacement - Bucket in Seats.
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