Dash Removal

I have a 1996 Camaro that I was told needs an Evaporator Core installed. The dealer said that it calls for 3.9 hours of labor and the cost would be around $400.00. I would like to try and do this myself but wouldn't want to get it started and get myself in a situation where I can't go any further. Anyone know what all is involved in removing the dash? I really appreciate the help!

Thanks,

Ryan

[1BADAIR]

Removal & Installation

CAUTION All models covered herein are equipped with a Supplemental Inflatable Restrain (SIR) System using multiple air bags. Whenever working near any of the SIR components, such as the impact sensors, the air bag module, steering column and instrument panel, make sure to properly disable the SIR system, as outlined in Section 6 of this manual. Failure to properly disarm the system may result in accidental air bag deployment, which could easily result in severe personal injury or death. Also, never attempt any electrical diagnosis or service to the SIR components and wiring; this work should only be performed by a qualified automotive technician.

1. Properly disable the SIR air bag system. Disconnect the negative battery cable.
2. Remove the left side instrument panel insulator, as follows:
   
   1. Remove the retainer from the instrument panel carrier.
   2. Remove the insulator from the instrument panel carrier by unhooking the flange on the insulator from the side kick panel, then detaching the tab on the insulator from the retainer on the instrument panel carrier.
3. Remove the right side instrument panel insulator, as follows:
   
   1. Remove the retainer from the boss on the heater and air conditioning module.
   2. Remove the retainer from the insulator.
   3. Remove the insulator from the instrument panel carrier by detaching the forward flange on the insulator from the boss on the heater and air conditioning module, then unhooking the flange on the insulator from the under the side kick panel.

Exploded view of the instrument panel insulator mounting
Click to Enlarge

1. Remove the window rail trim panel.
2. Remove the knee bolster and deflector.

Remove the drive side knee bolster
Unfasten the retaining nuts (A), then remove the deflector (B)
Remove the stoplamp switch before fully lowering the steering column. Failure to do so may cause the stoplamp switch to become damaged or thrown out of adjustment. This may result in a malfunctioning stoplamp or premature brake wear.

1. Remove the stoplamp switch.
2. Remove the steering column. Make sure to lower it gently, as not to damage it.
3. Remove the instrument panel upper trim panel, as follows:
   
   1. Remove the windshield side upper garnish moldings.
   2. Remove the security indicator lamp retainer, and/or the daytime running lamp ambient light sensor grille from the upper trim panel.
   3. Detach the panel from the carrier, carefully pulling up at the dual lock fasteners, then remove the panel from the vehicle.

The instrument panel upper trim panel is secure with dual lock fasteners

1. Remove the instrument panel accessory trim plate.
2. Unfasten the retaining bolts/screws or locating pins then remove the instrument panel cluster trim plate bezel.

The Chevrolet instrument panel cluster trim plate bezel is secured with retaining bolts/screws
Click to Enlarge The Pontiac instrument panel cluster trim plate bezel is secured with locating pins

1. Remove the instrument cluster from the vehicle, as outlined in Section 6 of this manual.
2. Remove the radio, heater and A/C temperature control panel, as outlined in Section 6 of this manual.

Remove the heater and A/C control panel

1. Remove the left side heater and A/C ducts.
2. Remove the transmission gear shift knob, cover and console, as outlined later in this section.
3. Remove the fuse block retaining bolt/screw, then remove the block from the instrument panel carrier.

Remove the retaining bolt, then remove the fuse block from the instrument panel carrier

1. Remove the Data Link Connector (DLC) by unfastening the two DLC-to-bracket bolts/screws and the three instrument panel bolts/screws attaching the bracket to the instrument panel carrier.
2. Remove the hazard and chime.
3. Unfasten the upper bolts/screws and lower nuts, then reposition the carrier.
4. Remove the air duct.
5. If equipped, remove the alarm assembly.
6. Tag and detach the wiring harness from the instrument panel carrier.
7. Remove the instrument panel carrier from the vehicle.

Typical instrument panel mounting
Click to Enlarge To install:

1. Place the instrument panel carrier in the vehicle, and attach the electrical connectors, as tagged during removal.

Instrument panel wire harness routing-Chevrolet vehicles
Click to Enlarge Instrument panel wire harness routing-Pontiac vehicles
Click to Enlarge

1. If equipped, install the alarm assembly.
2. Install the air duct.
3. Position the instrument panel, then install the lower retaining nuts. Tighten to 18 ft. lbs. (25 Nm). Install the upper bolts/screws and tighten to 17 inch lbs. (1.9 Nm).
4. Install the hazard and chime.
5. Install the DLC bracket and DLC and secure with the retainers.
6. Position the fuse block to the instrument panel carrier and secure with the retaining bolt/screw.
7. Install the console, cover and transmission gear shift knob.
8. Install the left side ducts.
9. Install the heater and A/C temperature control assembly, radio assembly and instrument cluster as outlined in Section 6 of this manual.
10. For Chevrolet, position the instrument cluster trim plate bezel over the carrier, insert the locating pins on the trim plate into the appropriate holes in the instrument panel. Align the holes on the bezel with the holes on the carrier. Install the retaining bolts/screws and tighten, in sequence, to 25 inch lbs. (2.8 Nm).
11. For Pontiac, position the instrument cluster trim plate bezel over the carrier, then fasten the locator pins attaching the bezel to the carrier.
12. Install the instrument panel accessory trim plate.
13. Install the instrument panel upper trim panel, as follows:
    
    1. Align the panel using the locator pins, then apply pressure to the back of the panel, engaging the dual lock fasteners with the mating surface.
    2. Install the security indicator lamp retainer, and/or daytime running lamp ambient light sensor grille to the upper trim panel.
    3. Install the left and right windshield upper garnish moldings.
14. Gently raise the steering column into position, then install as outlined in Section 6 of this manual.
15. Install the stoplamp switch.
16. Install the knee bolster and deflector.
17. Install the window rail trim panel.
18. If equipped, install the removable top.
19. Install the right side instrument panel insulator, as follows:
    
    1. Position the insulator to the instrument panel, hook the flange on the insulator over the side kick panel, then attach the forward flange on the insulator to the boss on the heater and air conditioning module.
20. Install the left side instrument panel insulator, as follows:
    
    1. Position the insulator to the instrument panel carrier, attach the tab on the insulator to the retainer on the instrument panel carrier, then hook the flange on the insulator to the side kick panel.
    2. Install the retainer to the instrument panel carrier.
21. Properly enable the SIR air bag system. Disconnect the negative battery cable.