GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Montana 🢒 Engine 🢒 Engine Cooling 🢒 Heater Core Cover Replacement

Removal Procedure
  1. Remove the right IP insulator. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gages and Console.
  2. Remove the left IP insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
  3. Remove the IP compartment. Refer to Instrument Panel Compartment Replacement in Instrument Panel, Gages and Console.
  4. Remove the center console brackets. Refer to Floor Console Bracket Replacement in Instrument Panel, Gages and Console.
  5. Disconnect the rear floor outlet duct from the heater outlet duct.
  6. Remove the rear floor outlet duct.
  7. If equipped, disconnect the DVD wiring harness from the IP support bracket.

    8. Object Number: 825398 Size: SH
  8. Remove the screws retaining the heater outlet duct.
  9. Remove the heater outlet duct.

    10. Object Number: 825396 Size: SH
  10. Remove the screws retaining the heater core cover.
  11. Remove the heater core cover.

Installation Procedure

    Object Number: 825396 Size: SH
  1. Install the heater core cover.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the heater core cover retaining screws.

    3. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).


    Object Number: 825398 Size: SH
  3. Install the heater outlet duct.
  4. Install the heater outlet duct screws.

    5. Tighten
    Tighten the screws to 1.6 N·m (14 lb in).

  5. If equipped, connect the DVD wiring harness to the IP support bracket.
  6. Install the rear floor outlet duct.
  7. Connect the rear floor outlet duct to the heater outlet duct.
  8. Install the center console brackets. Refer to Floor Console Bracket Replacement in Instrument Panel, Gages and Console.
  9. Install the IP compartment. Refer to Instrument Panel Compartment Replacement in Instrument Panel, Gages and Console.
  10. Install the left IP insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
  11. Install the right IP insulator. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gages and Console.