GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 General Information 🢒 General Information 🢒 Heater Core Cover Replacement

Removal Procedure
  1. Remove the body control module (BCM) from the vehicle. Refer to Body Control Module Replacement in Computer/Integrating Systems.

    2. Object Number: 877818 Size: SH
  2. Pull back the carpet at the bottom of the left instrument panel (I/P) center support bracket and remove the left I/P center support bracket nuts.
  3. Remove the left I/P center support bracket.
  4. Remove the accelerator control pedal from the front of the dash and position out of the way. Refer to Accelerator Pedal Position Sensor Replacement .

    5. Object Number: 873732 Size: SH
  5. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
  6. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage it from the HVAC module.

    7. Object Number: 877660 Size: SH
  7. Remove the heater core cover screws.

    8. Object Number: 872600 Size: SH

    Important: Make certain that all of the heater core cover screws are removed before attempting to remove the heater core cover.

  8. Pull the heater core cover down just enough to clear the locating pins from the HVAC module. Slide the heater core cover rearward until the drain tube clears the front of dash. Slide the heater core cover down, rearward, and to the right to remove.

Installation Procedure

    Object Number: 872602 Size: SH
  1. Install a new drain tube seal onto the drain tube.

    2. Object Number: 872600 Size: SH

    Important: Spraying the heater core seal and the dashmat with a soap and water mixture will ease installation.

  2. Install the heater core cover from the right side. Slide up and forward into position. Align the drain tube with the hole in the front of dash. Raise the heater core cover into position while aligning holes with the locating pins from the HVAC module.

    3. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 877660 Size: SH

    Important: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws.

  3. Install the heater core cover screws.

    4. Tighten
    Tighten the heater core cover screws to 1.8 N·m (15 lb in).


    Object Number: 877657 Size: SH
  4. Align the center floor duct with the HVAC module.
  5. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
  6. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
  7. Slide the center floor outlet duct down into position in the floor ducts.
  8. Install the accelerator control pedal. Refer to Accelerator Pedal Position Sensor Replacement .

    9. Object Number: 877818 Size: SH
  9. Pull back the carpet and place the left center support bracket into position.
  10. Install the left center support bracket nuts.

    11. Tighten
    Tighten the left center support bracket nuts to 10 N·m (88 lb in).


    Object Number: 877750 Size: SH
  11. Install the BCM to the vehicle. Refer to Body Control Module Replacement in Computer/Integrating Systems.