GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Dash and Cowl Panel Opening Cover Replacement

Removal Procedure
  1. Detach the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
  2. Detach the accelerator pedal module. Refer to Accelerator Pedal Position Sensor Replacement.
  3. Detach the brake pedal. Refer to Brake Pedal Assembly Replacement.
  4. Detach the clutch pedal. Refer to Clutch Pedal Replacement.

    5. Object Number: 1941508 Size: LF
  5. Detach the internal dash and cowl panel opening cover insulation.

    6. Remove the 4 snap buttons (1).

  6. Remove the battery support. Refer to Battery Tray Replacement.
  7. Release the coolant tank (1) and lay aside.

    8. Object Number: 1941523 Size: LF
  8. Release the ABS control/hydraulic modulator bracket (2).

    9. Remove the 2 bolts (3).


    Object Number: 1941511 Size: LF
  9. Remove the dash and cowl panel opening cover.
    10. • Remove the 7 nuts (arrows).
    • Remove the bolt (1).

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1941525 Size: LF

    Note: 

       • Apply urethane adhesive bead (1) as illustrated.
       • Use new nuts. Insert the bolt with screw locking compound.

  1. Install the dash and cowl panel opening cover.

    2. Apply urethane adhesive.

    Diameter of adhesive bead 8.0 mm (0.31 in).

    Tighten

        • Tighten the 7 nuts to 20 N·m (15 lb ft).
        • Tighten the bolt to 20 N·m (15 lb ft).
  2. Install the ABS control/hydraulic modulator bracket.

    3. Tighten
    Tighten the 3 bolts to 20 N·m (15 lb ft).

  3. Install the coolant tank.
  4. Install the battery support. Refer to Battery Tray Replacement.
  5. Attach the internal dash and cowl panel opening cover insulation.

    6. Install the 4 snap buttons.

  6. Install the clutch pedal. Refer to Clutch Pedal Replacement.
  7. Install the brake pedal. Refer to Brake Pedal Assembly Replacement.
  8. Install the accelerator pedal module. Refer to Accelerator Pedal Position Sensor Replacement.
  9. Install air distributor housing. Refer to HVAC Module Assembly Replacement.