GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Cavalier (CNG) 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Heater Outlet Hose Replacement

Removal Procedure
  1. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling in the J Platform Service Manual.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the J Platform Service Manual.

    3. Object Number: 927432 Size: SH
  3. Disconnect the clamps and remove the return hose assembly (5) from the high pressure regulator (HPR) underbody coolant line.
  4. Disconnect the clamps and remove the return hose assembly (7) from the heater core pipe.
  5. Lower the vehicle.
  6. Disconnect the clamp and remove the return hose assembly (8) from the engine pipe.
  7. Remove the heater hose retainers (2,3).

Disassembly Procedure

    Object Number: 762369 Size: SH
  1. Disconnect the clamp and remove the HPR hoses (7,8) from the coolant tee connector (3,4).
  2. Disconnect the clamp and remove the heater hoses (1,2) from the coolant tee connector (3,4).
  3. Disconnect the clamp and remove the engine coolant hoses (5,6) from the coolant tee connector (3,4).

Assembly Procedure

    Object Number: 762369 Size: SH
  1. Cut the engine pipe to heater core hose (5,6) as required in order to position the coolant tee (3,4).
  2. Place the remaining section of heater hose (1,2) on the opposite end of the coolant tee (3,4)
  3. Install the engine and heater hose clamps at the coolant tee connector (3,4).
  4. Install the proper cut length of coolant hose (6,7) at the coolant tee connector (3,4) HPR fitting.
  5. Install the HPR coolant hose clamps at the coolant tee connector.

Installation Procedure

    Object Number: 927432 Size: SH
  1. Connect the hose assembly (1) to the engine return (8) fitting and install the clamps.
  2. Install the heater hose retainers (2,3).
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the J Platform Service Manual.
  4. Connect the return hose assembly (7) to the heater core pipe. Install the clamps.
  5. Connect the return hose assembly (5) to the HPR underbody coolant line. Install the clamps.
  6. Lower the vehicle.
  7. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling in the J Platform Service Manual.