GM Corsica/Beretta 1988-1996 Repair Guide

Heater Core

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

Vehicles Without A/C
1988-90 VEHICLES

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Disconnect the heater inlet and outlet hoses from the heater core.
  6.  
  7. Remove the heater outlet deflector.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the heater core and related system components - 1988-90 vehicles without A/C

  1. Unfasten the retaining screws, then remove the heater core cover.
  2.  
  3. Remove the heater core retaining straps, then remove the heater core from the vehicle.
  4.  
  5. Installation is the reverse of removal.
  6.  

1991 VEHICLES

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Properly disable the SIR system, as outlined earlier in this section.
  6.  
  7. Remove the instrument panel as outlined in this section.
  8.  
  9. Remove the screws and floor outlet, turning clockwise and to the right to release from the rear floor air outlet.
  10.  
  11. Raise the vehicle and support it safely.
  12.  
  13. Detach the heater hoses from the heater core.
  14.  
  15. Disconnect the drain tube elbow from the heater core cover.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Unfasten the retaining screws, then remove the heater core cover.
  20.  
  21. Remove the core screws, clamps and heater core from the vehicle.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the heater core and related components - 1991-92 vehicles without A/C

To install:
  1. Reposition the heater core and install the straps and screws.
  2.  
  3. Install the heater core cover and attaching screws.
  4.  
  5. Install the floor outlet and retaining screws.
  6.  
  7. Install the instrument panel.
  8.  
  9. Raise the vehicle and support it safely.
  10.  
  11. Connect the heater hoses to the heater core.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Fill the cooling system with the proper type and amount of coolant.
  16.  
  17. Enable the SIR system, as outlined earlier in this section.
  18.  
  19. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  20.  

1992-93 VEHICLES

See Figure 2

  1. Disable the SIR system, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the radio as outlined in this section.
  8.  
  9. Reach through the radio opening and release the heater core cover from the retention clips.
  10.  
  11. Remove the screws and floor outlet, turning clockwise and to the right to release from the rear floor air outlet.
  12.  
  13. Raise the vehicle and support it safely.
  14.  
  15. Disconnect the heater hoses from the heater core.
  16.  
  17. Detach the drain tube elbow from the heater core cover.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Unfasten the retaining screws and remove the heater core cover.
  22.  
  23. Remove the core screws, clamps and heater core from the vehicle.
  24.  

To install:
  1. Reposition the heater core and install the straps and screws. Tighten the retaining screws to 12 inch lbs. (1.4 Nm).
  2.  
  3. Install the heater core cover and attaching screws. Tighten the cover attaching screws to 12 inch lbs. (1.4 Nm).
  4.  
  5. Reach through the radio opening, position the cover under the retention clips.
  6.  
  7. Install the radio.
  8.  
  9. Install the floor outlet and retaining screws.
  10.  
  11. Raise the vehicle and support it safely.
  12.  
  13. Connect the heater hoses to the heater core.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Fill the cooling system with the proper type and amount of coolant.
  18.  
  19. Enable the SIR system.
  20.  
  21. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  22.  

1994-96 VEHICLES

For heater core removal on these vehicles, please refer to the procedure for vehicles with A/C.

Vehicles With A/C
1988-90 VEHICLES

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Raise and safely support the front of the vehicle.
  6.  
  7. Disconnect the drain tube from the heater case.
  8.  
  9. Detach the heater hoses from the heater core.
  10.  
  11. Carefully lower the car.
  12.  
  13. Remove the right and left hush panels, the steering column trim cover, the heater outlet duct and the glove box.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the heater core and related components - 1988-90 vehicles with A/C

  1. Remove the heater core cover. Be sure to pull the cover straight to the rear so as not to damage the drain tube.
  2.  
  3. Remove the heater core clamps, then remove the core from the vehicle.
  4.  
  5. Installation is the reverse of the removal procedure.
  6.  
  7. Fill the cooling system with the proper type and amount of coolant.
  8.  
  9. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  10.  

1991 VEHICLES

See Figure 4b

  1. Disable the SIR system, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Remove the instrument panel as outlined in this section.
  8.  
  9. Remove the screws and floor outlet, turning clockwise and to the right to release from the rear floor air outlet.
  10.  
  11. Raise the vehicle and support it safely.
  12.  
  13. Disconnect the heater hoses from the heater core.
  14.  
  15. Detach the drain tube elbow from the heater core cover.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Remove the screws and remove the heater core cover.
  20.  
  21. Remove the core screws, clamps and heater core from the vehicle.
  22.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the heater core and related components - 1991-93 vehicles with A/C

To install:
  1. Reposition the heater core and install the straps and screws.
  2.  
  3. Install the heater core cover and attaching screws.
  4.  
  5. Install the floor outlet and retaining screws.
  6.  
  7. Install the instrument panel.
  8.  
  9. Raise the vehicle and support it safely.
  10.  
  11. Connect the heater hoses to the heater core.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Fill the cooling system with the proper type and amount of coolant.
  16.  
  17. Enable the SIR system.
  18.  
  19. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  20.  

1992-93 VEHICLES

See Figure 4

  1. Disable the SIR system.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Raise the vehicle and support it safely.
  8.  
  9. Disconnect the drain tube from the heater case.
  10.  
  11. Detach the heater hoses from the heater core.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Remove the console, if equipped.
  16.  
  17. Remove the right and left sound insulators.
  18.  
  19. Remove the steering column opening filler.
  20.  
  21. Remove the screws and floor outlet, turning clockwise and to the right to release from the rear floor air outlet.
  22.  
  23. Unfasten the retaining screws, then remove the heater core cover.
  24.  
  25. Remove the core screws, clamps and heater core from the vehicle.
  26.  

To install:
  1. Reposition the heater core and install the straps and screws. Tighten the screws to 12 inch lbs. (1.4 Nm).
  2.  
  3. Install the heater core cover and attaching screws. Tighten the screws to 12 inch lbs. (1.4 Nm).
  4.  
  5. Install the floor outlet and retaining screws.
  6.  
  7. Install the right and left sound insulators.
  8.  
  9. Install the console, if equipped.
  10.  
  11. Install the steering column opening filler.
  12.  
  13. Raise the vehicle and support it safely.
  14.  
  15. Attach the heater hoses to the heater core.
  16.  
  17. Connect the drain tube to the heater case.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Fill the cooling system with the proper type and amount of coolant.
  22.  
  23. Enable the SIR system.
  24.  
  25. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  26.  

1994-96 VEHICLES

See Figures 5, 6 and 7

  1. Properly disable the SIR system, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Disconnect the drain tube from the heater case.
  10.  
  11. Detach the heater hoses from the heater core.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Remove the right and left sound insulators.
  16.  
  17. Remove the steering column opening filler.
  18.  
  19. Remove the floor air outlet duct.
  20.  
  21. Remove the heater core cover.
  22.  
  23. Unfasten the heater core mounting clamps, then remove the heater core from the vehicle.
  24.  



Click image to see an enlarged view

Fig. Fig. 5: The heater core is located in the passenger's side footwell, below the glove compartment



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the heater core and related components (1 of 2) - 1994-96 vehicles



Click image to see an enlarged view

Fig. Fig. 7: Component list for the heater core and related system components (2 of 2) - 1994-96 vehicles

To install:
  1. Position the heater core in the vehicle and secure with the mounting straps.
  2.  
  3. Install the heater core cover.
  4.  
  5. Install the floor air outlet duct.
  6.  
  7. Install the right and left sound insulators.
  8.  
  9. Install the steering column opening filler.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Connect the heater hoses to the heater core.
  14.  
  15. Attach the drain tube to the heater case.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Enable the SIR system, as outlined earlier in this section.
  22.  
  23. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.
  24.  

 
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