This is for a Sunfire dash going into a Cavalier, but it'll work both ways.
I searched and saw alot of "Swapping dash's" and "Can I swap this/that"
So since I've done the above,, thought I'd post a quick how-to.
If anyone has anything to add, or something I missed/got wrong let me know or fix it.
If I posted this in the wrong forum, or shouldn't of posted it at all.. just delete it.
If not.. maybe it'd be a useful sticky!
I wish I took more pictures during the swap.
But I think the few pictures speak for themselves.
The parts needed from the sunfire:
lower dash
dash topper pad
dash cover(piece up/under windscreen)
Sub-frame(large metal frame attached to firewall)
All HVAC plumbing
door panels
Steering wheel(optional, weighs less then cavalier wheel)
door panel support(attached to doors with rivets, optional)
Cluster(optional, requires lots of re-wiring)
HVAC face(if want red HVAC face)
Center console(Optional)
Tools:
7mm Socket(most of the bolts are this size)
8mm Socket(for the little gold/bronze bolts, I find it works better then 7mm)
22mm(might of been 21mm) for the steering wheel bolt
Steering wheel puller
Set of torq bits(for the blinker/washer control arms, don't recall size)
Hacksaw/Razor blade(minor cutting is required)
Drill w/ drill bits(used for small minor details)
Modifications needed:
The old door braces for the Cavalier need to come off-
Drill out the rivets and they will come off.
Cluster-
This is the biggest issue I found with the swap, theres 2 ways;
Cut up the Cavalier cluster and the Sunfire dash and MAKE it fit.
OR wire up the Sunfire cluster(not as easy as it sounds).
The Cavalier HVAC needs a small knob on the backside cut off to fit
Lets get started...
Find a donor car:
(this will work)
Remove the upper dash pad from both cars(7mm bolts):
Most people should know how to do this, so I'm not posting pics.
Remove the lower dash as well(7mm, 8mm bolts):
(steering wheel has been removed already)
This is what will be under the lower dash:
A few 8mm and 4 larger size bolts*dont recall size* on the ends;
(don't forget to remove the fuse box and Cluster/Dome light switch)
And the sub-frame will come right out:
Here is the whole Cavalier dash removed:
*Now, these steps use pictures from both cars,
but ultimately they are the same minus a few bolts in different locations*
Now to put the Sunfire dash in the Cavalier...
Put the Sunfire sub-frame in:
*Note make sure you don't "lose" any of the wiring durring these steps*
Then the lower dash:
*Note there is a plastic piece under the glovebox that I could not get to fit in the Cavalier, I removed this piece*
Now.. either you can wire in the Sunfire cluster, or make the Cavalier cluster fit.(I went with the Cavalier cluster)
Put on the dash topper pad:
One plus with the Sunfire dash.. is the HVAC is on the bottom and the Stereo goes on top now YAY!
Now the door panels, sadly I didn't take any pictures.
But its pretty straight forward as well.
You just have to remove the small metal brackets from the Cavalier doors.
The sunfire door panels dont use the metal brackets by the top of the doors like the Cavalier(mine didn't at least).
The 3 screws at the bottom of the panels fit with the Cavalier, but you will have to drill a hole for the side screw on the Sunfire panel.
The Entire dash and door panels are all you need for the swap.
All the other trim is the same on both cars.
You could do a Cavalier dash swap into the sunfire the same way.
I know I didn't go into super detail on this, but most of it is pretty straight forward. If you have any questions feel free to ask.
<img src="http://www.majhost.com/gallery/HCAJosh/crap/shooshined.jpg">
- putting the pieces back together -
