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Eric
Eric, Automotive Repair Shop Manager
Category: Pontiac
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Experience:  20+ yrs. experience as repair shop manager and technician.
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How to replace a heater core on a 2004 pontiac grandprix

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how to replace a heater core on a 2004 pontiac grandprix

Hi,

 

To access the heater core in this model there is an extensive amount of work thats required to get to that point and this even requires removal of the front seats and pull back the carpet to remove the rear heater duct work. Below are directions:

 

Drain the coolant.

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  1. Use hose clamp pliers in order to position aside the heater hose inlet and outlet clamps at the heater core.
  2. Disconnect the inlet and outlet heater hose from the heater core.

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  4. Remove 3 fasteners on the right hand under dash insulator.
  5. Rotate the lamp. Remove the lamp from the insulator.
  6. Remove the insulator.

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  7. Remove 3 fasteners from the drivers side under dash insulator.

     

  8. Rotate the lamp. Remove the lamp from the insulator.

  9. Remove the insulator.
  10. Remove the front seats.
  11. Remove the front floor console, if equipped.
  12. Remove the carpet retainers.

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  1. Using a trim panel tool remove the push-in retainers which position the carpet on top of the rocker panels.
  2. Remove the carpet from the vehicle.
  3. Remove the rear floor air outlet duct from the holes in the floor reinforcement.
  4. Disconnect the rear floor air outlet duct from the heater core outlet cover.
  5. Remove the rear floor air outlet duct.
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  6. Remove the heater core outlet cover screws (2).
  7. Remove the heater core outlet cover heat stakes (1) with a small chisel.
  8. Remove the heater core outlet cover from the HVAC module assembly.
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  9. Remove the heater core cover screws (2).
  10. Remove the heater core cover heat stakes (1) with a small chisel.
  11. Remove the heater core cover from the HVAC module assembly.
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  12. Remove the heater core from the HVAC module assembly.



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  13. Install a new heater core foam seal (1) to the HVAC module assembly.
  14. Install the heater core to the HVAC module assembly.
  15. From the inside of the heater core cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.
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  16. Install the heater core cover.

     

  17. Install the heater core cover screws to the heater core cover.

    Tighten
    Tighten all the screws to 1.5 N·m (13 lb in).

  18. From the inside of the heater core outlet cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.
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  19. Install the heater core outlet cover.
  20. Install the heater core outlet cover screws (2).

    Tighten
    Tighten the screws to 1.5 N·m (13 lb in).

  21. Connect the rear floor air outlet duct to the heater core outlet cover.
  22. Install the rear floor air outlet duct to the holes in the floor reinforcement.
  23. Install the floor carpet.
  24. Install the RH Instrument Panel Closeout/Insulator panel.
  25. Install the RH Instrument Panel Closeout/Insulator panel.
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  26. Connect the inlet and outlet heater hose to the heater core.
  27. Use a trim panel tool in order to reposition the heater hose inlet and outlet clamps to the heater core.
  28. Refill the coolant.
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