GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Cavalier 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Heater Core Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Disconnect the heater hoses from the heater core.
  4. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
  5. Remove the heater core outlet.
  6. Remove the heater core cover. The heater core cover mounting screw is located in a recess in the center of the cover.
  7. Remove the following components:
    8. • The heater core mounting clamps
    • The heater core

Installation Procedure

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the following components:
    2. • The heater core
    • The heater core mounting clamps

    Tighten
    Tighten the screws to 1 N·m (9 lb in).

  2. Install the heater core cover.

    3. Tighten
    Tighten the screws to 1 N·m (9 lb in).

  3. Install the heater core outlet.

    4. Tighten
    Tighten the screws to 1 N·m (9 lb in).

  4. Install the instrument panel. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges and Console.
  5. Connect the heater hoses to the heater core.
  6. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Connect the negative battery cable.

    8. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).