GM Corsica/Beretta 1988-1996 Repair Guide

Instrument Panel and Pad Assembly

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CAUTION
Some vehicles are equipped with the Supplemental Inflatable Restraint (SIR) or air bag system. The SIR system must be disabled, as outlined in Chassis Electrical , before performing service on or around SIR system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary SIR system repairs.

REMOVAL & INSTALLATION



1988-90 Vehicles

See Figure 1

The instrument panel can be removed with some of its components left in place. Unless removal is necessary for component service, leave as much in place as possible. It may be easier to remove later on a workbench.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cluster assembly.
  4.  
  5. Disconnect the electrical connectors from the steering column.
  6.  
  7. Remove the accessory center.
  8.  
  9. Remove the right sound insulator.
  10.  
  11. Remove the right instrument panel compartment.
  12.  
  13. Disconnect the electrical connectors behind the passengers side of the instrument panel by reaching through the glove compartment opening.
  14.  
  15. Disconnect the antenna by reaching through the glove compartment opening.
  16.  
  17. Remove the left compartment.
  18.  
  19. Detach the electrical connectors from the fuse block by reaching through the left compartment opening.
  20.  
  21. Remove the defroster grille.
  22.  
  23. Remove the speaker covers by prying gently with a suitable tool to release them from the 2 spring clips.
  24.  
  25. Reach under the driver's side of the instrument panel and remove the cover from the junction block.
  26.  
  27. From under the hood, remove the cover from the junction block on the driver's side of the cowl. Remove the 2 nuts from the junction block retainer and the 1 bolt from the center junction block retainer.
  28.  
  29. Remove the junction block from the cowl by reaching under the instrument panel.
  30.  
  31. Disconnect the electrical connector from the lower left side of the heater module.
  32.  
  33. Remove the 2 nuts holding the wiring harness and clutch neutral start switch at the cowl, on manual transaxle cars.
  34.  
  35. Remove the 2 bolts from the defroster opening.
  36.  
  37. Remove the 1 bolt from each speaker opening.
  38.  
  39. Remove the 1 bolt at the lower front on each side of the instrument panel.
  40.  
  41. Remove the instrument panel.
  42.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the instrument panel pad assembly

To install:
  1. Position the instrument panel into the vehicle.
  2.  
  3. Install the 2 bolts at the lower front.
  4.  
  5. Install the 2 bolts through the speaker openings.
  6.  
  7. Install the 2 bolts through the defroster opening.
  8.  
  9. Install the 2 nuts holding the wiring harness to the cowl.
  10.  
  11. Attach the electrical connector to the lower left side of the heater module.
  12.  
  13. Install the junction block to the cowl by reaching under the instrument panel.
  14.  
  15. From under the hood, Install the 2 nuts from the junction block retainer and the 1 bolt from the center junction block retainer. Install the cover on the junction block.
  16.  
  17. Install the speaker covers by pressing into place.
  18.  
  19. Install the defroster grille.
  20.  
  21. Install the electrical connectors to the fuse block.
  22.  
  23. Install the left compartment.
  24.  
  25. Connect the antenna lead.
  26.  
  27. Attach the electrical connectors behind the passengers side of the instrument panel by reaching through the glove compartment opening.
  28.  
  29. Install the right instrument panel compartment.
  30.  
  31. Install the right side sound insulator.
  32.  
  33. Install the accessory center.
  34.  
  35. Install the cluster assembly.
  36.  
  37. Attach the electrical connections at the steering column.
  38.  

1991-96 Vehicles

See Figures 2 and 3

Disable the Supplemental Inflatable Restraint (SIR) system, as outlined in Chassis Electrical of this information.

  1. Remove the cluster bezel and cluster assembly.
  2.  
  3. Remove the trim bezel.
  4.  
  5. Remove the heater, air conditioner and radio controls.
  6.  
  7. Remove the knee bolster panel.
  8.  
  9. Lower the steering column.
  10.  
  11. Detach the Assembly line Diagnostic Link (ALDL) connector.
  12.  
  13. Remove the convenience center and bracket.
  14.  
  15. Remove the turn signal bracket.
  16.  
  17. Remove the left center brace bolt from the instrument panel.
  18.  
  19. Disconnect the left side window defogger hose from the heater module.
  20.  
  21. Remove the instrument panel compartment.
  22.  
  23. Remove the right sound insulator.
  24.  
  25. Remove the cruise control module mounting screws and move the module to one side.
  26.  
  27. Remove the wire harness retainer screw.
  28.  
  29. Remove the air distributor screws.
  30.  
  31. Remove the right side window defogger outlet duct.
  32.  
  33. Remove the right/center brace bolts and nuts from the instrument panel.
  34.  
  35. Remove the right and left pillar nuts.
  36.  
  37. Remove the windshield defroster grille.
  38.  
  39. Remove the upper instrument panel screws.
  40.  
  41. Disconnect the left side wire retainers and rotate the instrument panel to gain access to the right side.
  42.  
  43. Detach the cluster connection and wiring harness clips to the instrument panel.
  44.  
  45. Disconnect the knee bolster brace.
  46.  
  47. Disconnect the center wire harness retainer screws.
  48.  
  49. Disconnect the fuse block.
  50.  
  51. Disconnect the wire retainer on the right of the steering column.
  52.  
  53. Remove the instrument panel pad from the vehicle.
  54.  
  55. Disconnect the right and left window defogger outlets.
  56.  
  57. Disconnect the right and left defogger outlet nozzles.
  58.  
  59. Disconnect the left center air outlets.
  60.  
  61. Disconnect the right side outlet assembly (cup holder).
  62.  
  63. Remove the bracket from the right side of the instrument panel.
  64.  
  65. Remove the knee bolster reinforcement on the left side of the steering column.
  66.  
  67. Remove the pillar studs.
  68.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the instrument panel pad assembly - 1991-96 vehicles



Click image to see an enlarged view

Fig. Fig. 3: Location of the instrument panel wiring harness connectors - 1991-96 vehicles

To install:
  1. Install the pillar studs to the instrument panel.
  2.  
  3. Install the knee bolster reinforcement on the left side of the steering column.
  4.  
  5. Install the bracket on the right side of the instrument panel.
  6.  
  7. Connect the right side outlet assembly (cup holder).
  8.  
  9. Attach the left center air outlets.
  10.  
  11. Connect the right and left defogger outlet nozzles.
  12.  
  13. Attach the right and left window defogger outlets.
  14.  
  15. Position the air distributor and wire harness in an approximate location in the vehicle.
  16.  
  17. Position the instrument panel pad in approximate location in the vehicle.
  18.  
  19. Install the knee bolster bracket and bolts and tighten 58 inch lbs. (6.5 Nm).
  20.  
  21. Connect the cluster connection and wiring harness clips to the instrument panel.
  22.  
  23. Install the air distributor screws.
  24.  
  25. Connect the right side window defogger outlet nozzle to the instrument panel and duct to air distributor.
  26.  
  27. Locate the instrument panel assembly on the windshield lower frame and body hinge pillars.
  28.  

Make sure the knee bracket interlocks with the U-shaped support on the dash panel.

  1. Install the screws to the windshield lower frame.
  2.  
  3. Install the nuts to the pillar studs.
  4.  
  5. Install the right and center brace, bolts and nuts and tighten the bolts to 58 inch lbs. (6.5 Nm) and the nuts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the right wire harness retainer screw.
  8.  
  9. Position the cruise control module to the air distributor and install the retaining screws.
  10.  
  11. Install the instrument panel compartment and lamp electrical connection.
  12.  
  13. Connect the left side window defogger duct to the heater module.
  14.  
  15. Install the left center brace bolt to the instrument panel pad.
  16.  
  17. Secure the turn signal flasher to the clip on the convenience center bracket.
  18.  
  19. Install the convenience center.
  20.  
  21. Raise the steering column and tighten the retaining bolts to 20 ft. lbs. (27 Nm).
  22.  
  23. Install the ALDL connector.
  24.  
  25. Position the knee bolster panel and tighten the screws to 13 inch lbs. (1.5 Nm).
  26.  
  27. Install the radio receiver.
  28.  
  29. Install the heater and air conditioner control.
  30.  
  31. Install the trim bezel and instrument cluster.
  32.  
  33. Enable the SIR system as outlined in Chassis Electrical .
  34.  
  35. Install the right and left sound insulators.
  36.  

 
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