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Removal Installation

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					PATH: Heating, Ventilation, & Air Conditioning > Heater Core > Removal &
Installation
 Removal & Installation

    Animations and Tech Tips




        Click to view: Disconnecting coolant hoses and refrigerant lines
                      1.  Disable the SIR system, as outlined in this section. See below.
                      2.  Disconnect the negative battery cable.
                      3.  Properly drain the cooling system.
                      4.  Raise and safely support the vehicle.
                      5.  Detach the heater hoses from the heater core.
                      6.  Carefully lower the vehicle.
                      7.  Remove the instrument panel. For details, please refer to the
                          procedure located in Section 10 of this manual. See below.
                      8. Remove the DERM with the attaching bracket.
                      9. Detach the heater core cover.
                      10. Unfasten the heater core mounting clamps, then remove the heater
                          core.
          Exploded view of the heater core and related components
                              Click to Enlarge
To install:
         11. Position the heater core, then secure with the mounting clamps.
         12. Attach the heater core cover.
         13. Install the DERM with the attaching bracket.
         14. Install the instrument panel, as outlined in Section 10 of this
             manual.
         15. Raise and safely support the vehicle.
         16. Connect the heater hoses to the core.
17. Carefully lower the vehicle.
18. Properly refill the engine cooling system and check for leaks.
19. Enable the SIR system.
20. Connect the negative battery cable, then start the engine and
    check for proper system operation and/or leaks.
1. Disable the SIR system by performing the following procedure:
        Point the wheel in the straight-ahead position.
        Turn the ignition switch to the LOCK position.
        Remove the AIR BAG fuse from the fuse block.
        At the base of the steering column, remove the left sound
           insulator.
        At the base of the steering column, disconnect the
           Connector Position Assurance (CPA), the yellow 2-way
           electrical connectors and the passenger’s side module
           electrical connector.
2. Disconnect the negative battery cable.
3. Drain the cooling system into a clean container for reuse.
4. Disconnect the heater hoses from the heater core.




     Air distribution duct mounting—Cavalier shown
                    Click to Enlarge
Location of the air distribution duct mounting—Sunfire
                          shown
                  Click to Enlarge
Detach the instrument panel lamp connector—Cavalier
                     and Sunfire
                 Click to Enlarge
    Instrument panel-to-tie bar attachments—Cavalier
                    Click to Enlarge




      Instrument panel-to-tie bar mounting—Sunfire
                    Click to Enlarge
9. If equipped, remove the Diagnostic Energy Reserve Module
    (DERM) with attaching brackets.
10. Remove the steering wheel by removing or disconnecting the
    following:
         SIR module-to-steering wheel screws
         SIR module and disconnect the electrical connector

                         CAUTION
Place the SIR module in a safe place with the front facing upward.

             Steering wheel-to-steering column nut
            Steering wheel from the steering column
   11. Remove the instrument panel by removing or disconnecting the
       following:
            Defroster grille
            Instrument panel end caps from both sides
            Instrument panel trim pad, (Cavalier models only)
            Accessory trim plate, (Sunfire models only)
            Instrument panel trim plate
            Heater/air conditioning control assembly
            Radio
            Air ventilation ducts from the heater housing
            Instrument panel light electrical connector
            Tie bar screws
            Instrument panel from the tie bar
            Heater core outlet screws and the outlet
            Heater core cover-to-heater case screws and the cover.

                               NOTE




The heater core mounting screw is located in the recess in the
center of the heater core cover.

             Heater core clamp from the heater assembly
             Heater core from the heater assembly
              Exploded view of the heater/evaporator housing
                     assembly—Cavalier and Sunfire
                             Click to Enlarge
To install:
         1. Install or connect the following:
                 Heater core to the heater assembly
                 Heater core clamp to the heater assembly and torque the
                     clamp screws to 9 inch lbs. (1 Nm)
                 Heater core cover and the cover-to-heater case screw and
                     torque the screws to 9 inch lbs. (1 Nm)
                 Heater core outlet and torque the screws to 9 inch lbs. (1
                     Nm)
                 Diagnostic Energy Reserve Module (DERM) with
                     attaching bracket, if equipped
         2. Install the instrument panel by installing or connecting the
            following:
                 Instrument panel to the tie bar
                 Tie bar screws
                 Instrument panel light electrical connector
                 Air ventilation ducts to the heater housing
                 Radio
                 Heater/air conditioning control assembly
                 Instrument panel trim plate
                 Instrument panel trim pad, (Cavalier models only)
                 Accessory trim plate, (Sunfire models only)
                 Instrument panel end caps on both sides
                 Defroster grill
                 Heater hoses to the heater core
         3. Install the steering wheel by installing or connecting the
            following:
                 Steering wheel to the steering column
                 Steering wheel-to-steering column nut and torque the nut
                     to 30 ft. lbs. (41 Nm)
                 Electrical connector and install the SIR module
                 SIR module-to-steering wheel screws and torque the
                     screws to 89 inch lbs. (10 Nm)
         4. Refill the cooling system.
         5. Connect the negative battery cable.
         6. Enable the SIR system by performing the following procedure:
                 Turn the ignition switch to the LOCK position.
          At the base of the steering column, connect the Connector
           Position Assurance (CPA), the yellow 2-way electrical
           connectors and the passenger’s side module electrical
           connector.
        At the base of the steering column, install the left sound
           insulator.
        Install the AIR BAG fuse to the fuse block.
        Turn the ignition switch to the RUN position; the INFL
           REST warning light should flash 7–9 times then turn OFF.
7. Operate the engine to normal operating temperatures; then, check
   the climate control operation and check for leaks.

				
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posted:5/29/2011
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