GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Heater Core Replacement

Removal Procedure

    Object Number: 1251918 Size: SH
  1. Raise the hood.

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable.
  3. Remove the instrument panel assembly from the vehicle. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
  4. Remove the heater/air distribution case from the vehicle. Refer to HVAC Module Assembly Replacement .
  5. Remove the linkage screw from the lower heater core cover post.
  6. Remove the linkage lever. Note the position of all the levers to facilitate reassembly.

    7. Object Number: 1251917 Size: SH

    Notice: Handle the case carefully to avoid damage to the linkage levers.

  7. Remove the screws that secure the heater core cover.

    8. Object Number: 1251915 Size: SH
  8. Slowly separate the lower heater core cover from the rest of the assembly. Retain the sealant.
  9. Remove the screw and the bracket clamp that secure the heater core lines to the case.
  10. Remove the spring clamp that secures the heater core body to the case.
  11. Remove the heater core from the case.

Installation Procedure

    Object Number: 1251915 Size: SH
  1. Install the heater core into the case.
  2. Secure the heater core lines to the case with the retaining bracket clamp and the screw.
  3. Install the heater core body with the retaining spring clamp.
  4. Reapply the sealant to the heater core cover mounting channel flange as removed.

    5. Object Number: 1251917 Size: SH
  5. Install the heater core cover.
  6. Install the retaining screws.
  7. Install the linkage lever onto the cover post with the screw.
  8. Confirm proper operation of the actuating levers for the heater/air distribution case doors.

    9. Object Number: 1251918 Size: SH
  9. Install the heater/air distribution case. Refer to HVAC Module Assembly Replacement .
  10. Install the instrument panel assembly. Refer to Instrument Panel Assembly Replacement in Instrument Panel, Gages and Console.
  11. Fill the cooling system.
  12. Connect the negative battery cable.