Express, Savana, G1500, G2500, G3500, 1998-2005

Removal & Installation

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  1. Drain the engine cooling system into a clean container for reuse.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Heater hoses from the heater core
     
    Surge tank (diesel) or the coolant recovery reservoir (except diesel).
     
    Positive battery cable, the battery hold-down and the battery
     
    Refrigeration lines from the air conditioning accumulator and discard the gaskets
     
    Air conditioning accumulator
     
    Lower right kick panel and the knee bolster, from the right side
     
    Lower outer floor air outlet duct
     
    Heater case screws
     

  6.  
  7. Carefully open the heater core access door.

    Heater core-to-heater case retainers and the heater core

    Click image to see an enlarged view

    Fig. Under hood view of the heater assembly-Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater case screws-Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater core and retainers-Express and Savana

     

  8.  

To install:

  1. Install or connect the following:

    Heater core and the heater core-to-heater case retainers. Carefully, close the heater core access door.
     
    Heater case screws
     
    Lower outer floor air outlet duct
     
    Knee bolster and the lower right kick panel
     
    Air conditioning accumulator.
     
    Refrigeration lines to the air conditioning accumulator, using new gaskets
     
    Battery, the battery hold-down and the positive battery cable
     
    Surge tank (diesel) or the coolant recovery reservoir (except diesel)
     
    Heater hoses to the heater core
     

  2.  
  3. Evacuate and charge the air conditioning system.
  4.  
  5. Refill the engine cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

  1. Drain the engine cooling system into a clean container for reuse.
  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Heater hoses from the heater core
     
    Positive battery cable, the battery hold-down and the battery
     
    Refrigeration lines from the air conditioning accumulator and discard the gaskets
     
    Air conditioning accumulator
     
    Lower right kick panel and the knee bolster, from the right side
     
    Lower outer floor air outlet duct
     
    Heater case screws
     

  6.  
  7. Carefully open the heater core access door.

    Heater core-to-heater case retainers and the heater core

    Click image to see an enlarged view

    Fig. Under hood view of the heater assembly-Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater case screws-Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater core and retainers-Express and Savana

     

  8.  

To install:

  1. Install or connect the following:

    Heater core and the heater core-to-heater case retainers. Carefully, close the heater core access door.
     
    Heater case screws
     
    Lower outer floor air outlet duct
     
    Knee bolster and the lower right kick panel
     
    Air conditioning accumulator.
     
    Refrigeration lines to the air conditioning accumulator, using new gaskets
     
    Battery, the battery hold-down and the positive battery cable
     
    Heater hoses to the heater core
     

  2.  
  3. Evacuate and charge the air conditioning system.
  4.  
  5. Refill the engine cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

Front



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Remove the surge tank (diesel) or the coolant recovery reservoir (except diesel).
  10.  
  11. Remove the positive battery cable, the battery hold-down and the battery.
  12.  
  13. Disconnect the refrigeration lines from the air conditioning accumulator and discard the gaskets.
  14.  
  15. Remove the air conditioning accumulator.
  16.  
  17. From the right side, remove the lower right kick panel and the knee bolster.
  18.  
  19. Remove the lower outer floor air outlet duct.
  20.  
  21. Remove the heater case screws.
  22.  
  23. Carefully open the heater core access door.
  24.  
  25. Remove the heater core-to-heater case retainers and the heater core.

    Click image to see an enlarged view

    Fig. Underhood view of the heater assembly-Chevy/GMC Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater case screws-Chevy/GMC Express and Savana



    Click image to see an enlarged view

    Fig. View of the heater core and retainers-Chevy/GMC Express and Savana

  26.  

To install:

  1. Install the heater core and the heater core-to-heater case retainers.
  2.  
  3. Carefully, close the heater core access door.
  4.  
  5. Install the heater case screws.
  6.  
  7. Install the lower outer floor air outlet duct.
  8.  
  9. To the right side, install the knee bolster and the lower right kick panel.
  10.  
  11. Install the air conditioning accumulator.
  12.  
  13. Using new gaskets, connect the refrigeration lines to the air conditioning accumulator.
  14.  
  15. Install the battery, the battery hold-down and the positive battery cable.
  16.  
  17. Install the surge tank (diesel) or the coolant recovery reservoir (except diesel).
  18.  
  19. Evacuate and charge the air conditioning system.
  20.  
  21. Connect the heater hoses to the heater core.
  22.  
  23. Refill the engine cooling system.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

Rear Heater Core



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the rear auxiliary heater core.
  6.  
  7. From the left rear side, remove the rear interior quarter trim panel.
  8.  
  9. Remove the blower motor from the rear auxiliary heater case.
  10.  
  11. Remove the rear auxiliary heater case retainers and the case.
  12.  
  13. Remove the lower auxiliary heater case retainers and the lower case.
  14.  
  15. Remove the rear heater core from the case.

    Click image to see an enlarged view

    Fig. View of the rear auxiliary heater core, case and retainers-Chevy/GMC Express and Savana

  16.  

To install:

  1. Install the rear auxiliary heater core to the case.
  2.  
  3. Install the lower case and the lower auxiliary heater case retainers.
  4.  
  5. Install the rear auxiliary heater case retainers and the case.
  6.  
  7. Install the blower motor from the rear auxiliary heater case.
  8.  
  9. To the left rear side, install the rear interior quarter trim panel.
  10.  
  11. Connect the heater hoses to the rear auxiliary heater core.
  12.  
  13. Refill the engine cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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