GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Cooling 🢒 Heater Core Replacement

Removal Procedure

    Object Number: 1936855 Size: LF

    Note: Depressurize cooling system by opening and re-closing closure cap on coolant compensation tank.

  1. Drain the coolant.

    2. Collect the coolant in a drip pan.

  2. Remove the blower module drain hose (1).

    3. Remove the 2 bolts.

    Note: Mark the coolant hose (3) and connection (2) before removal to avoid confusion when refitting.

  3. Disconnect the 2 coolant hoses.

    4. Release the 2 quick-release fittings.


    Object Number: 1936372 Size: SH
  4. For vehicles equipped with the heater housing insulator, remove the air inlet screen (1).
  5. For vehicles equipped with the heater housing insulator, remove the windshield wiper arms (2).
  6. Remove the 2 covers.

    7. Remove the 2 nuts.

  7. Remove the 2 washers.
  8. Remove the 2 wiper arms from the shaft.

    9. Object Number: 1936369 Size: LF

    Note: Carefully release the clips from the dash bracket from inside outward.

  9. For vehicles equipped with the heater housing insulator, remove the air inlet screen (1).
    10. 9.1. Lift the air inlet screen in the dash area.
    9.2. Release the 5 clips (3).
    9.3. Remove the hose (2) for the windshield washer system.

    Object Number: 1937175 Size: LF
  10. For vehicles equipped with the heater housing insulator, detach the air duct housing from the dash outside.

    11. Remove the 8 bolts.

  11. Remove the front floor console. Refer to Front Floor Console Replacement.

    12. Object Number: 1937099 Size: LF
  12. For vehicles equipped with air conditioning (A/C), remove the air duct rear footwell (1).
  13. Remove the front floor console bracket right.

    14. Object Number: 1937109 Size: LF
  14. Detach and remove the heater core cover.

    15. Remove the 8 bolts (1, 2).

  15. For vehicles equipped with the heater housing insulator, remove the insulator.
  16. Remove the heater core with heater pipes.
  17. Detach the heater pipes.

    18. Detach the 2 heater pipes.

Installation Procedure
  1. Install the heater pipes to the heater core.

    2. Replace the 2 sealing rings.

    Note: With the aid of an assistant, guide the heater pipes through the splash panel.

  2. Insert the heater core.

    3. Note:  Only on vehicles with insulator.

  3. For vehicles equipped with an insulator, install the insulator.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the heater core cover.

    5. Tighten
    Tighten the 8 bolts to 6 N·m (53 lb in).

  5. Install the right center console bracket.

    6. Tighten
    Tighten the 2 bolts to 13 N·m (113 lb in).

  6. Install the air duct rear footwell.
  7. Install the front floor console. Refer to Front Floor Console Replacement.
  8. For vehicles equipped with an insulator, attach the air duct housing to the dash outside.

    9. Tighten
    Tighten the 8 bolts to 6 N·m (53 lb in).

  9. For vehicles equipped with an insulator, fit the air inlet screen.
    10. 9.1. Attach the screen washer hose.
    9.2. Clip in the 5 clips.

    Note: Ensure the windshield wiper arms are correctly positioned.

  10. For vehicles equipped with an insulator, install the windshield wiper arms.
    11. 10.1. Install the 2 wiper arms to the shaft.
    10.2. Install the 2 washers.

    Tighten
    Tighten the 2 nuts to 17 N·m (13 lb ft).

    10.3. Install the 2 cover caps.
  11. For vehicles equipped with an insulator, install the air inlet screen.

    12. Object Number: 1936671 Size: LH

    Note: The following installation sequence must be observed.

  12. Install the coolant hoses to heater core.
    13. 12.1. Slide the 2 locks on the quick-release fittings in the arrow direction up to the stop.
    12.2. Plastic rings (green) are covered.
    12.3. Install the 2 quick-release fittings on the heater core (1) connections up to the stop.
    12.4. Note the markings applied. Slide the 2 locks (3) on the quick-release fittings in the arrow direction up to the stop.
    12.5. Plastic rings (green) must be visible.
    12.6. Inspect the correct seat of quick-release fittings and visibility of the plastic rings (arrows).
  13. Install the drain hose.

    14. Tighten
    Tighten the 2 bolts to 5 N·m (44 lb in).

  14. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling.

    15. Note: Inspect for leaks with utmost care as hot coolant will escape into the drivers footwell if there are leaks in coolant connections at the heater core.

  15. Inspect the coolant system for leaks. Refer to Cooling System Leak Testing.