Contents: Astra Models ⬇ Zafira Models ⬇
The models of vehicles covered in this manual are equipped with a supplemental restraint system (SRS). Before performing any work near the air bag unit, steering column or instrument panel, turn off the SRS to avoid injury from accidental deployment (see Chapter On-board electrical equipment). The SRS circuit wiring is easily identified by the yellow color of the insulation.
See also the illustrative material provided in Chapter User manual.
Astra Models
1. Disconnect the negative battery cable. Wait at least one minute before proceeding with the upcoming work, during which time the SRS independent power supply capacitor should discharge.
2. Remove the center console and ashtray (see Removal and installation the glove box).
3. Remove the mat, then use a screwdriver to release the upper and lower fasteners.
4. Remove the storage box from the dashboard.
5. Remove the radio and its mounting box (see Chapter On-board electrical equipment). On models equipped with a navigation system, remove the latter unit (see Chapter On-board electrical equipment).
6. Using a screwdriver, release the locks of the heater control handles through the resulting hole and remove them from the control panel.
7. Unscrew the lower mounting bolts and carefully remove the decorative trim from the instrument panel.
8. Then disconnect the electrical wiring from the multifunction display assembly.
9. Remove the hazard warning switch (see Chapter On-board electrical equipment) and disconnect its electrical wiring. If necessary, remove the mounting screws and remove the multifunction display from the panel.
10. Remove the lighting control switch installed on the driver's side of the instrument panel (see Chapter On-board electrical equipment). Loosen the mounting screws and remove the side air duct deflector and switch from the instrument panel.
11. After turning the deflector downwards through the fixed position, access to the mounting screws should open through its grille.
12. If the deflector is difficult to turn, remove the screws through the grille, then release the side fasteners and turn the deflector before installing.
13. Release the deflector from the instrument panel and remove the screws from it.
14. Disconnect the electrical wiring from the housing of the lighting control switch and lower the latter down.
15. Remove the glove box (see Removal and installation the glove box).
16. Turn the right side air duct deflector downwards and unscrew the mounting screws through its grille.
17. Also unscrew the deflector mounting bolt and remove the latter from the instrument panel.
18. Disconnect the electrical wiring from the passenger airbag module through the opening for installing the glove box - try not to damage the terminals of the contact connector.
19. Remove the steering wheel (see Chapter Suspension and steering). Remove the lower left trim section from the instrument panel.
Installation diagram of the lower sections of the instrument panel trim
20. Remove the mounting screws and remove the upper and lower sections of the steering column cover (see Chapter Suspension and steering).
21. Remove the steering column switches (see Chapter On-board electrical equipment).
22. Remove the instrument cluster (see Chapter On-board electrical equipment).
23. Remove the storage box from the left side of the instrument panel.
A — Schematic diagram of the location of the fastening fasteners of the driver's box for small items
B - Unscrewing the mounting screws
C - Removing the small box from the instrument panel
A.
B.
C.
24. To expand the work space, remove both front seats (see Removal and installation front seats).
25. Carefully remove the inner sill trims, unscrew the mounting screws and remove the front corner sill trims.
26. Disconnect the electrical wiring from the rear of the instrument panel - try to remember the route of the harnesses.
27. Remove the lower right section of the instrument panel trim (see Removal and installation of interior trim panels) and a hose supplying air to the passenger footwell.
28. Separate the windshield air supply hose deflector from the instrument panel.
29. Under the windshield, unscrew the three screws securing the front panel to the engine compartment bulkhead - the side screws are covered with plastic plugs.
A — Front instrument panel mounting screws
B — Side screw for fastening the instrument panel (the plastic plug has been removed)
A.
B.
30. Make sure that all electrical wiring is disconnected and nothing interferes with the removal of the instrument panel.
31. With the help of an assistant, carefully separate the panel from the engine compartment bulkhead and carefully remove it from the vehicle interior.
32. Installation is carried out in the reverse order. Ensure that the electrical wiring is laid correctly. A description of the installation procedures for the side air duct deflectors is given in Chapter Cooling and heating systems.
Zafira Models
1. Disconnect the negative battery cable. Wait at least one minute before proceeding with the upcoming work, during which time the SRS independent power supply capacitor should discharge.
2. Remove the center console and ashtray (see Removal and installation the glove box).
3. Remove the heater control panel (see Chapter Cooling and heating systems).
4. Remove the steering wheel (see Chapter Suspension and steering).
5. Remove the steering column switches (see Chapter On-board electrical equipment).
6. Remove the ignition switch (see Chapter On-board electrical equipment).
7. Remove the radio and its mounting box (see Chapter On-board electrical equipment). On models equipped with a navigation system, remove the latter unit (see Chapter On-board electrical equipment).
8. Using a small screwdriver, release the fasteners and remove the lighting control switch.
9. Using a pair of small screwdrivers, insert the screwdriver into the hole where the switch is installed, release the clips and remove the switch panel - note that the wiring connector remains inside the instrument panel.
10. Remove the fuse box cover.
11. Remove the upper section of the side vent grille from the outside of the instrument panel, remove the screws securing the instrument panel trim panel - all screws above the panel, one screw in the upper outer corner, one screw inside the grille of the upper inner corner and four screws at the bottom.
A - Removing the upper section of the side deflector grille
B — Unscrewing the side screw securing the decorative trim of the instrument panel
C - The internal screw can be removed through the deflector grille
A.
B.
C.
12. Remove the decorative trim from the instrument panel and disconnect the electrical wiring.
13. Remove the instrument cluster (see Chapter On-board electrical equipment), - do not forget to disconnect the electrical wiring.
14. Loosen the nut and screw securing the fuse box, release the wiring harness from the holder inside the instrument panel mounting hole and loosen the plastic clamp.
15. Remove the mounting block and set it aside.
16. Pry with a wide-blade slotted screwdriver (or with a spatula), carefully remove the front decorative trim installed under the windshield from the instrument panel.
A — Releasing the fasteners of the front decorative trim of the instrument panel
B - Removing the front trim from the instrument panel
A.
B.
17. Remove the plastic plugs, unscrew the mounting screws and remove the decorative trims from the A-pillars.
18. Also remove the outer trim sections on both sides of the instrument panel.
19. Remove the front side trim panels on both sides of the passenger compartment, then remove the lower trim panels from the A-pillars.
20. Remove the glove box (see Removal and installation the glove box).
21. Remove the right air duct deflector.
22. Remove the mounting screws.
23. Remove the deflector housing.
24. Remove the lower instrument panel trim sections (see Removal and installation the center console), release the fasteners and remove the lower air ducts of the heating/ventilation systems.
25. Disconnect the contact connectors of the electrical wiring laid under the instrument panel - try to remember the order of connection and the route of the harnesses.
26. Remove the plugs and unscrew the instrument panel mounting screws. Also remove the seals from the door openings in the instrument panel area.
A — Unscrewing the front instrument panel mounting screws
B - The mounting screws are located under the plastic caps
A.
B.
27. With the help of an assistant, carefully separate the instrument panel from the engine compartment bulkhead and remove it from the passenger compartment.
28. Installation is carried out in the reverse order. Ensure that the electrical wiring is laid correctly. A description of the installation procedures for the side air duct deflectors is given in Chapter Cooling and heating systems.
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