GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Instrument Panel Carrier Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
  3. Remove the defroster grille. Refer to Defroster Grille Replacement .
  4. Remove the outer trim covers. Refer to Instrument Panel Outer Trim Cover Replacement .
  5. Remove the instrument panel (I/P) compartment. Refer to Instrument Panel Compartment Replacement .
  6. Remove the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  7. Remove the left front and right front sound insulators. Refer to Instrument Panel Insulator Panel Replacement - Right Side and to Instrument Panel Insulator Panel Replacement - Left Side .
  8. Remove the steering wheel. Refer to Steering Wheel Replacement in Steering Wheel and Column.
  9. Remove the multifunction switch. Refer to Multifunction Turn Signal Lever Replacement - On Vehicle in Steering Wheel and Column.
  10. Remove the I/P cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement .
  11. Remove the I/P accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement .
  12. Remove the I/P cluster. Refer to Instrument Cluster Replacement .
  13. Remove the HVAC controls. Refer to HVAC Module Assembly Replacement in HVAC Systems-Manual.
  14. Remove the radio and the remote cassette player. Refer to Radio Replacement and Remote Tape Player Replacement in Entertainment.
  15. Remove the ignition switch bolts. Refer to Ignition and Start Switch Replacement .

    16. Object Number: 743456 Size: SH
  16. Disconnect the outboard electrical connectors from the I/P wiring harness junction blocks.
  17. Remove the center console. Pull the console rearward in order to disengage the console from the I/P. Refer to Console Replacement .
  18. Remove the ashtray from the I/P carrier.

    19. Object Number: 291465 Size: SH
  19. Remove the screws (2,3,4) connecting the I/P carrier (1) to the cross vehicle beam (6).
  20. Remove the I/P carrier (1) from the cross vehicle beam (6).

Installation Procedure

    Object Number: 291465 Size: SH
  1. Install the I/P carrier (1) to the cross vehicle beam (6).

    2. 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.

  2. Install the screws (2,3,4) connecting the I/P carrier (1) to the cross vehicle beam (6).

    3. Tighten
    Tighten the screws to 2.3 N·m (20 lb in).

  3. Install the ashtray.
  4. Install the center console. Refer to Console Replacement .

    5. Object Number: 743456 Size: SH
  5. Connect the outboard electrical connectors to the I/P wiring harness junction blocks.
  6. Install the ignition switch bolts. Refer to Ignition and Start Switch Replacement .
  7. Install the radio and the remote cassette player. Refer to Radio Replacement and Remote Tape Player Replacement in Entertainment.
  8. Install the HVAC controls. Refer to HVAC Module Assembly Replacement in HVAC Systems-Manual.
  9. Install the I/P cluster. Refer to Instrument Cluster Replacement .
  10. Install the I/P cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement .
  11. Install the I/P accessory trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement .
  12. Install the multifunction switch. Refer to Multifunction Turn Signal Lever Replacement - On Vehicle in Steering Wheel and Column.
  13. Install the steering wheel. Refer to Steering Wheel Replacement in Steering Wheel and Column.
  14. Install the passenger side SIR inflator module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR.
  15. Install the left and right sound insulators. Refer to Instrument Panel Insulator Panel Replacement - Right Side and Instrument Panel Insulator Panel Replacement - Left Side .
  16. Install the outer trim covers. Refer to Instrument Panel Outer Trim Cover Replacement .
  17. Install the I/P compartment. Refer to Instrument Panel Compartment Replacement .
  18. Install the defroster grille. Refer to Defroster Grille Replacement .
  19. Enable the SIR system. Refer to Enabling the SIR System in SIR.