Alero, Grand Am 1999-2005

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the drain tube from the heater housing.
  8.  
  9. Disconnect the heater hoses from the heater core.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove or disconnect the following:

    Console, if equipped
     
    Sound insulators from both sides
     
    Steering column opening filler
     
    Air outlet duct
     
    Rear floor air outlet screws and the outlet
     
    Heater core cover
     
    Heater core-to-housing mounting clamps and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components

     

  14.  

To install:

  1. Install or connect the following:

    Heater core and the heater core-to-housing mounting clamps
     
    Heater core cover
     
    Rear floor air outlet and the outlet screws
     
    Air outlet duct
     
    Steering column opening filler
     
    Sound insulators, if equipped
     
    Console, if equipped
     
    Heater hoses to the heater core.
     
    Drain tube to the heater housing.
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures. Check the climate control operation and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disable the Supplemental Inflatable Restraint (SIR) system, as outlined in the Chassis Electrical Section.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Remove or disconnect the following:

    Evaporator hose from the evaporator
     
    Heater hoses
     
    Drain tube elbow
     
    Heater case plate for the heater pipes
     
    Heater case plate for the evaporator block
     
    End caps
     
    Sound insulators
     
    Instrument panel compartment
     
    Passenger inflator module
     
    Tilt steering lever
     
    Upper and the lower steering column covers
     
    Hazard warning switch
     
    Instrument panel cluster trim plate
     
    Instrument panel cluster
     
    Driver inflator module
     
    Steering wheel
     
    Multifunction lever
     
    Accessory trim plate
     
    Radio
     
    Cup holder
     
    Gearshift handle
     
    Ignition switch bolts
     
    Instrument panel upper bolt covers
     
    Electrical junction box connections
     
    Fog lamp switch
     
    Windshield side upper garnish molding
     
    Console from the instrument panel
     
    Instrument panel from the tie bar
     
    Air distribution duct
     
    Floor air duct
     
    Tie bar
     
    Daytime Running Lights (DRL) sensor wiring harness from the Heating, Ventilation, Air Conditioning (HVAC) module
     
    Blower motor electrical connectors
     
    Temperature actuator electrical connector
     
    HVAC module from the vehicle
     
    Heater core case cover
     
    Heater core bracket
     
    Heater core
     

  10.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core bracket. Torque the screw to 9 inch lbs. (1 Nm).
     
    Heater core case cover. Torque the screws to 9 inch lbs. (1 Nm).
     
    HVAC module
     
    Temperature actuator electrical connector
     
    Blower motor electrical connectors
     
    DRL wiring harness
     
    Tie bar. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Floor air duct. Torque the bolts to 18 inch lbs. (2 Nm).
     
    Air distribution duct. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Instrument panel
     
    Console to the instrument panel
     
    Windshield side upper garnish molding
     
    Fog lamp switch
     
    Electrical junction box connections
     
    Instrument panel upper bolt covers
     
    Ignition switch bolts
     
    Gearshift handle
     
    Cup holder
     
    Radio. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Accessory trim plate
     
    Multifunction lever. Torque the screw to 35 inch lbs. (4 Nm).
     
    Steering wheel. Torque the nut to 27 ft. lbs. (37 Nm).
     
    Driver inflator module. Torque the screw to 89 inch lbs. (10 Nm).
     
    Instrument panel cluster
     
    Instrument panel cluster trim plate
     
    Hazard warning switch
     
    Upper and the lower steering column covers. Torque the screw to 18 inch lbs. (2 Nm).
     
    Tilt steering lever
     
    Passenger inflator module. Torque the fasteners to 89 inch lbs. (10 Nm).
     
    Instrument panel compartment
     
    Sound insulators
     
    End caps
     
    Heater case plate for the evaporator block. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Heater case plate for the heater pipes
     
    Drain tube elbow
     
    Heater hoses
     
    Evaporator hose. Torque the fitting to 18 ft. lbs. (25 Nm).
     

  2.  
  3. Fill the engine cooling system.
  4.  
  5. Evacuate and recharge the A/C system.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disable the Supplemental Inflatable Restraint (SIR) system, as outlined in the Chassis Electrical Section.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Remove or disconnect the following:

    Evaporator hose from the evaporator
     
    Heater hoses
     
    Drain tube elbow
     
    Heater case plate for the heater pipes
     
    Heater case plate for the evaporator block
     
    End caps
     
    Sound insulators
     
    Instrument panel compartment
     
    Passenger inflator module
     
    Tilt steering lever
     
    Upper and the lower steering column covers
     
    Hazard warning switch
     
    Instrument panel cluster trim plate
     
    Instrument panel cluster
     
    Driver inflator module
     
    Steering wheel
     
    Multifunction lever
     
    Accessory trim plate
     
    Radio
     
    Cup holder
     
    Gearshift handle
     
    Ignition switch bolts
     
    Instrument panel upper bolt covers
     
    Electrical junction box connections
     
    Fog lamp switch
     
    Windshield side upper garnish molding
     
    Console from the instrument panel
     
    Instrument panel from the tie bar
     
    Air distribution duct
     
    Floor air duct
     
    Tie bar
     
    Daytime Running Lights (DRL) sensor wiring harness from the Heating, Ventilation, Air Conditioning (HVAC) module
     
    Blower motor electrical connectors
     
    Temperature actuator electrical connector
     
    HVAC module from the vehicle
     
    Heater core case cover
     
    Heater core bracket
     
    Heater core
     

  10.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core bracket. Torque the screw to 9 inch lbs. (1 Nm).
     
    Heater core case cover. Torque the screws to 9 inch lbs. (1 Nm).
     
    HVAC module
     
    Temperature actuator electrical connector
     
    Blower motor electrical connectors
     
    DRL wiring harness
     
    Tie bar. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Floor air duct. Torque the bolts to 18 inch lbs. (2 Nm).
     
    Air distribution duct. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Instrument panel
     
    Console to the instrument panel
     
    Windshield side upper garnish molding
     
    Fog lamp switch
     
    Electrical junction box connections
     
    Instrument panel upper bolt covers
     
    Ignition switch bolts
     
    Gearshift handle
     
    Cup holder
     
    Radio. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Accessory trim plate
     
    Multifunction lever. Torque the screw to 35 inch lbs. (4 Nm).
     
    Steering wheel. Torque the nut to 27 ft. lbs. (37 Nm).
     
    Driver inflator module. Torque the screw to 89 inch lbs. (10 Nm).
     
    Instrument panel cluster
     
    Instrument panel cluster trim plate
     
    Hazard warning switch
     
    Upper and the lower steering column covers. Torque the screw to 18 inch lbs. (2 Nm).
     
    Tilt steering lever
     
    Passenger inflator module. Torque the fasteners to 89 inch lbs. (10 Nm).
     
    Instrument panel compartment
     
    Sound insulators
     
    End caps
     
    Heater case plate for the evaporator block. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Heater case plate for the heater pipes
     
    Drain tube elbow
     
    Heater hoses
     
    Evaporator hose. Torque the fitting to 18 ft. lbs. (25 Nm).
     

  2.  
  3. Fill the engine cooling system.
  4.  
  5. Evacuate and recharge the A/C system.
  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the drain tube from the heater housing.
  8.  
  9. Disconnect the heater hoses from the heater core.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove or disconnect the following:

    Console, if equipped
     
    Sound insulators from both sides
     
    Steering column opening filler
     
    Air outlet duct
     
    Rear floor air outlet screws and the outlet
     
    Heater core cover
     
    Heater core-to-housing mounting clamps and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-Grand Am, Achieva and Skylark

     

  14.  

To install:

  1. Install or connect the following:

    Heater core and the heater core-to-housing mounting clamps
     
    Heater core cover
     
    Rear floor air outlet and the outlet screws
     
    Air outlet duct
     
    Steering column opening filler
     
    Sound insulators, if equipped
     
    Console, if equipped
     
    Heater hoses to the heater core.
     
    Drain tube to the heater housing.
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Operate the engine to normal operating temperatures. Check the climate control operation and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disable the Supplemental Inflatable Restraint (SIR) system.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Remove or disconnect the following:

    Evaporator hose from the evaporator
     
    Heater hoses
     
    Drain tube elbow
     
    Heater case plate for the heater pipes
     
    Heater case plate for the evaporator block
     
    End caps
     
    Sound insulators
     
    Instrument panel compartment
     
    Passenger inflator module
     
    Tilt steering lever
     
    Upper and the lower steering column covers
     
    Hazard warning switch
     
    Instrument panel cluster trim plate
     
    Instrument panel cluster
     
    Driver inflator module
     
    Steering wheel
     
    Multifunction lever
     
    Accessory trim plate
     
    Radio
     
    Cup holder
     
    Gearshift handle
     
    Ignition switch bolts
     
    Instrument panel upper bolt covers
     
    Electrical junction box connections
     
    Fog lamp switch
     
    Windshield side upper garnish molding
     
    Console from the instrument panel
     
    Instrument panel from the tie bar
     
    Air distribution duct
     
    Floor air duct
     
    Tie bar
     
    Daytime Running Lights (DRL) sensor wiring harness from the Heating, Ventilation, Air Conditioning (HVAC) module
     
    Blower motor electrical connectors
     
    Temperature actuator electrical connector
     
    HVAC module from the vehicle
     
    Heater core case cover
     
    Heater core bracket
     
    Heater core
     

  10.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core bracket. Torque the screw to 9 inch lbs. (1 Nm).
     
    Heater core case cover. Torque the screws to 9 inch lbs. (1 Nm).
     
    HVAC module
     
    Temperature actuator electrical connector
     
    Blower motor electrical connectors
     
    DRL wiring harness
     
    Tie bar. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Floor air duct. Torque the bolts to 18 inch lbs. (2 Nm).
     
    Air distribution duct. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Instrument panel
     
    Console to the instrument panel
     
    Windshield side upper garnish molding
     
    Fog lamp switch
     
    Electrical junction box connections
     
    Instrument panel upper bolt covers
     
    Ignition switch bolts
     
    Gearshift handle
     
    Cup holder
     
    Radio. Torque the bolts to 27 inch lbs. (3 Nm).
     
    Accessory trim plate
     
    Multifunction lever. Torque the screw to 35 inch lbs. (4 Nm).
     
    Steering wheel. Torque the nut to 27 ft. lbs. (37 Nm).
     
    Driver inflator module. Torque the screw to 89 inch lbs. (10 Nm).
     
    Instrument panel cluster
     
    Instrument panel cluster trim plate
     
    Hazard warning switch
     
    Upper and the lower steering column covers. Torque the screw to 18 inch lbs. (2 Nm).
     
    Tilt steering lever
     
    Passenger inflator module. Torque the fasteners to 89 inch lbs. (10 Nm).
     
    Instrument panel compartment
     
    Sound insulators
     
    End caps
     
    Heater case plate for the evaporator block. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Heater case plate for the heater pipes
     
    Drain tube elbow
     
    Heater hoses
     
    Evaporator hose. Torque the fitting to 18 ft. lbs. (25 Nm).
     

  2.  
  3. Fill the engine cooling system.
  4.  
  5. Evacuate and recharge the A/C system.
  6.  

 
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