Question about 1991 Chevrolet Cavalier

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Replacing a heater core

I have a 1991 Chevy Cavalier, automatic, 4 cylinder without A/C, floor shift console, 2 door sedan that I need to replace the heater core. I need instructions or pictures of how to dismantle the dashboard to install this. Any help you could give me would be greatly appreciated.

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  • Anonymous Mar 13, 2014

    was driveing then steam started comeing out dashboard
    cant tell if its a hose or what water is leeking outside of the truck floor is dry

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  • Master
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YOU DO NOT NEED TO REMOVE THE DASH BOARD. IT WILL BE BEHIND THE GLOVE BOX. LOOK UNDERNEATH THE DASH AND YOU WILL NEED TO REMOVE A PANEL TO GAIN ACCESS TO THE HEATER CORE. THE PANEL WILL BE ABOVE THE PASSENGERS FEET ON THE FIREWALL.

Posted on Jan 24, 2009

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Posted on Jan 02, 2017

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Removing heater core


This is for a 2.3L
Hope this helps, it it does please leave feedback Thank You and Good Luck

REMOVAL
  1. Disconnect battery ground cable.
  2. Drain cooling system.
  3. Raise and support vehicle.
  4. Disconnect heater hoses from heater core assembly.
  5. Remove drain tube.
  6. Lower vehicle.
  7. If equipped, remove console as follows:
    1. Apply parking brake and block drive wheels.
    2. Position transaxle shift lever in Neutral.
    3. On models with automatic transaxle, remove clip retaining shift lever handle to lever, then remove shift lever handle.
    4. On models with manual transaxle, turn shift lever handle counterclockwise to remove from lever.
    5. On all models, carefully pry upward on outer edges of console trim plate.
    6. Disconnect electrical connectors and ashtray lamp from console trim plate, then remove trim plate from console.
    7. Remove console to mounting bracket attaching screws, then remove console.
  1. Right and left sound insulators.
  2. Steering column opening filler.
Floor Air Duct Outlet 58917672

  1. Floor air outlet duct.
  2. Heater core cover.
  3. Heater core mounting clamps and remove heater core.
INSTALLATION
  1. Heater core and heater core mounting clamps.
  2. Heater core cover.
  3. Floor air outlet duct.
  4. Right and left sound insulators.
  5. Console.
  6. Steering column opening filler.
  7. Raise vehicle.
  8. Heater hoses to heater core.
  9. Drain tube to heater case.
  10. Lower vehicle.
  11. Negative battery cable.
  12. Fill cooling system and check for leaks.

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How to replace heater hose. they are the hoses a e back of the engine by the fire wall


Taurus And Sable - Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION After disconnecting the negative battery cable, wait for at least 1 minute for the SRS or air bag module to deplete its energy.

  2. Place the front wheels in the straight-ahead position.
  3. Lock the steering column.
  4. Remove or disconnect the following:
    SRS bolt covers from both sides of the steering wheel SRS module-to-steering wheel bolts SRS module and disconnect the electrical connector Steering wheel bolt and discard it
  5. Press the steering wheel from the steering column.
    Lower steering column shaft bolt 2 lower instrument panel cover-to-instrument panel screws and unsnap the lower cover from the instrument panel
  6. Turn ignition switch to the RUN position
  7. Insert a 1 / 8 in. (3mm) wire or pin punch in the lower steering column shroud hole, under the ignition switch; then, press on the pin while pulling out on the ignition switch lock cylinder and remove it from the steering column lock cylinder housing.
  8. Remove or disconnect the following:
    3 steering column shroud screws and the shrouds Shift control selector lever boot Gearshift lever pin from the manual control lever and remove the lever Wiring connector at the bottom of the steering column and remove the wiring from the column, (if equipped with an overdrive lockout switch on the manual control lever) Electrical connectors Multi-function switch screws and move it aside Shift indicator cable from the shifter tube Shifter indicator-to-column adjustment cable screw Interlock cable and actuator (if equipped with a column shift) 4 steering column-to-instrument panel bracket nuts and steering column Push pins and the lower instrument cover from the instrument panel reinforcement (at the passenger-s side) Console finish panel
  9. Under the steering column, 2 instrument panel brace screws, the courtesy lamp socket, the 2 Diagnostic Link Connector (DLC) screws and the instrument panel brace.
  10. If not equipped with an Electronic Automatic Temperature Control (EATC), disconnect the electrical connectors and the vacuum harness from the evaporator housing and the blower motor.
  11. If equipped with an Electronic Automatic Temperature Control (EATC), remove the sensor hose/elbow and disconnect the electrical harness connectors and the vacuum hose harness from the evaporator housing.
  12. Insert the Radio Removing tools 415-001into the integrated control panel faceplate; then, push the tools in approximately 1 1 / 2 in. (38mm) to release the retaining clips. Spread the tools slightly and pull the integrated control panel from the instrument panel.
  13. Remove or disconnect the following:
    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped 6 console center finish panel screws and the panel, (if equipped with a floor shift) 4 instrument panel finish panel screws and panel, located at the right side of the steering column, (if equipped with a column shift) Instrument cluster finish panel-to-instrument panel clips and pull the finish panel straight out 4 instrument cluster-to-instrument panel screws, the electrical connectors and the instrument cluster Upper finish panel (located at the top of the instrument panel) Light sensor amplifier connector, (if equipped with an autolamp) Instrument panel finish end panels on both sides of the instrument panel Front scuff plates and pull the door weatherstrip away from the instrument panel (on both sides of the instrument panel) 3 instrument panel-to-upper cowl top panel screws 2 screws at each end of the instrument panel Instrument panel electrical connectors and the parking brake switch Instrument panel
  14. Drain the cooling system into a clean container for reuse
  15. Remove or disconnect the following:
    WARNING Do not attempt to bend any part of the lever, for it is brittle and will break. Heater hoses from the heater core and plug the openings 4 air conditioning electronic blend door actuator-to-heater/air conditioning housing assembly screws and the actuator Metal cover, disengage the spring from the heater core cover and from the lever Gently, depress the locking ramp and remove the lever from the secondary air temperature control door end
  16. Rotate the primary air conditioning air temperature control door shaft downward, swing the metal link counterclockwise and remove it from the pin.
  17. Remove the 3 heater core cover-to-heater/air conditioning housing assembly screws, the cover and the seal.
  18. Press on the heater core tubes and remove the heater core from the heater/air conditioning housing assembly.

Hope helps (remember rated this).

May 28, 2010 | 2002 Ford Taurus

1 Answer

Need to replace heater core. 91 Cavalier RS, 4 cyl., 2 litre


  1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  3. Remove the bolt connecting evaporator lines to evaporator.
  4. Remove the evaporator lines from the evaporator.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Disconnect the heater hoses from the heater core.
  7. Lower the vehicle.
  8. Remove the evaporator case drain tube.
  9. Remove the inside and outside module attaching bolts and the accumulator mounting bracket bolt.
  10. Remove the IP carrier.
  11. Remove the floor air outlet.
  12. Disconnect the wiring harness from the HVAC module assembly
  13. Disconnect the electrical connections at the following locations:
  1. Remove the HVAC module assembly screw (2) at the top of the module from the mounting bracket. (1).
  2. Disconnect the gray source vacuum line (1). IMPORTANT: DO NOT tilt HVAC module assembly or coolant may leak out.
  3. Remove MODULE from Vehicle

Jul 28, 2009 | 1991 Chevrolet Cavalier

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