GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Sunfire 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Heater Core Replacement

Removal Procedure
  1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement .

    2. Object Number: 869079 Size: SH
  2. Remove the heat stakes and the screws from the heater cover case.
  3. Remove the heater cover case.

    4. Object Number: 869071 Size: SH
  4. Remove the heater core from the HVAC module assembly.

Installation Procedure

    Object Number: 869071 Size: SH
  1. Install the heater core to the HVAC module assembly.

    2. Object Number: 869079 Size: SH
  2. Install the heater core cover case.

    3. 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.

  3. Install the heater core cover case screws.

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

  4. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement .