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Eric, Automotive Repair Shop Manager
Category: Pontiac
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How do you change a heater core in a 1998 sunfire?

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how do you change a heater core in a 1998 sunfire?

Hi,

 

Heater core replacement requires removal of instrument panel(dashboard):

 

Airbag Disable:

With the AIR BAG fuse removed and the ignition switch

ON, the AIR BAG warning lamp will be on. The is normal and does not indicate any system malfunction.

  1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.

  2. Turn the ignition switch to LOCK, remove the key, then disconnect the negative battery cable.

  3. Remove the AIR BAG fuse from the fuse block.

  4. Remove the steering column filler panel.

  5. Disengage the Connector Position Assurance (CPA) and both yellow two way connectors and corresponding CPAs located near the base of the steering column.

  6. Connect the negative battery cable.

 

ENABLING THE SYSTEM

See Figure 6

  1. Disconnect the negative battery cable.

  2. Turn the ignition switch to LOCK, then remove the key.

  3. Engage both yellow SIR connectors and corresponding CPAs located near the base of the steering column.

  4. Install the steering column filler panel.

  5. Install the AIR BAG fuse to the fuse block.

  6. Connect the negative battery cable.

  7. Turn the ignition switch to RUN and make sure that the AIR BAG warning lamp flashes seven times and then shuts off. If the warning lamp does not shut off, make sure that the wiring is properly connected. If the light remains on, take the vehicle to a reputable repair facility for service.

graphic

 

Instrument Panel:

 

  1. If equipped, disable the SIR system, as outlined in Chassis Electrical of this guide.

  2. If not done already, disconnect the negative battery cable.

  3. Unfasten the defroster grille retaining screw, then remove the grille.

  4. To remove the instrument panel end-caps, unfasten the end-cap retaining screws and remove the cap.


graphic


Fig. 2: Location of the air distribution duct mounting-Sunfire shown

 


 

  1. Remove the instrument cluster trim plate.
  2. As outlined in Chassis Electrical of this guide, remove the heater and A/C control panel.

  3. Remove the radio assembly, as outlined in Chassis Electrical of this guide.

  4. Unfasten the air distribution ducts.


 

graphic
Fig. 5: Instrument panel-to-tie bar mounting-

 

  1. Detach the instrument panel compartment lamp electrical connector.

  2. Unfasten the screws to the tie bar, then remove the instrument panel from the tie bar.

To install:

  1. Position the instrument panel to the tie bar, then secure with the retaining screws.

  2. Attach the instrument panel compartment lamp connector.

  3. Fasten the air distribution ducts.

  4. Install the radio and the heater and A/C control.

  5. Install the instrument cluster trim plate.

  6. Install the end caps.

  7. Position the defroster grille, then secure with the retaining screw,

  8. Enable the SIR system, if equipped. For details, please refer to the procedure located in Chassis Electrical of this guide.

  9. Connect the negative battery cable.

 

Heater Core:

See Figure 1

  1. Disable the SIR system, as outlined in this section.

  2. Disconnect the negative battery cable.

  3. Properly drain the cooling system.

  4. Raise and safely support the vehicle.

  5. Detach the heater hoses from the heater core.

  6. Carefully lower the vehicle.

  7. Remove the instrument panel. For details, please refer to the procedure located in Body & Trim of this guide.

  8. Remove the DERM with the attaching bracket.

  9. Detach the heater core cover.

  10. Unfasten the heater core mounting clamps, then remove the heater core.


: Exploded view of the heater core and related components

graphic

 

To install:

  1. Position the heater core, then secure with the mounting clamps.

  2. Attach the heater core cover.

  3. Install the DERM with the attaching bracket.

  4. Install the instrument panel, as outlined in Body & Trim of this guide.

  5. Raise and safely support the vehicle.

  6. Connect the heater hoses to the core.

  7. Carefully lower the vehicle.

  8. Properly refill the engine cooling system and check for leaks.

  9. Enable the SIR system.

  10. Connect the negative battery cable, then start the engine and check for proper system operation and/or leaks.

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