Heater Core Replacement Procedures

1991 Chevrolet Corsica
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1991 Chevrolet Corsica

Before you start removing your vehicle components, be sure you have your new heater core, heater hoses, clamps, coolant, and all other parts you will need for the job. Once you begin, you will not be able to drive the vehicle until the job is completed.

NOTE:  For your convenience, we have included a link to heater cores that fit this vehicle. We encourage you to help keep the information on this site free by purchasing your heater core and other needed parts through one of the links on this page.  

Amazon - You can usually get great deals from Amazon due to their low prices, no sales tax (depending on your location) and free shipping (on selected items.)  We highly recommend checking Amazon before you go to the local auto parts store.

Amazon -  New Heater Cores for 1991 Chevy Corsica

Other Replacement Parts for the Heater on Your 1991 Chevy Corsica  

Over 6,000 Other Parts for Your 1991 Chevy Corsica

You can also use this handy parts locator:

 

 

HEATER CORE REMOVAL

Source: wiki.answers.com

1. Disconnect the negative (-) battery cable.

2, Drain the coolant.

3. Disconnect the heater hoses from 

2. Remove both front seats. (2 bolts hold each seat).

3. Remove the 4 screws holding the glove compartment and then remove the glove compartment.

4. Remove the two panels that cover the underside of the dash. (3 screws and a pin bolt on each.)

5. Remove the passenger side kick plate (in front of the door.) and disconnect the speaker. You need to remove this to get to the nut that holds the passenger side dash.

6. Loosen the lower part of the dash by removing 2 nuts in the bottom outside corners and 2 bottom screws on 2 brackets toward the center of the dash.

7. Remove the two bolts holding the steering wheel to the dash. The steering wheel will remain in place but will drop down a little to allow you to pull the dash out a couple of inches. Now with a little force you can pull the dash out about 2 inches which is enough.

NOTE 1: There are 2 plastic covers that cover the heater core. The first one deflects hot air to the back seat. This cover is held on by 2 screws in the center and 2 clips toward the radio. You need to force the dash out to get to the clips.

NOTE 2: Now you need to remove the heater core cover. I believe there were 4 screws on the passenger side and three on the driver side. Careful. There are also 2 hidden screws in this cover. One is in an indention toward the center and the other is in an indention in toward the firewall. Remove this cover and you will see the heater core.

There are 2 metal brackets held by 4 screws that hold the heater core in.

Reverse the above to install the new heater core..

We had the car running in 5 hours and we took an hour or so to find the 2 hidden screws described above.

Good luck. From what I hear we saved around $800.

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Here is another heater core replacement procedure for the 1991 Chevy Corsica from JustAnswer.com:

 

  1. Disable the SIR system, ( see Disable SIR Below)

  2. Disconnect the negative battery cable.

  3. Drain the cooling system into a suitable container.

  4. Remove the instrument panel as outlined in this section.

  5. Remove the screws and floor outlet, turning clockwise and to the right to release from the rear floor air outlet.

  6. Raise the vehicle and support it safely.

  7. Disconnect the heater hoses from the heater core.

  8. Detach the drain tube elbow from the heater core cover.

  9. Carefully lower the vehicle.

  10. Remove the screws and remove the heater core cover.

  11. Remove the core screws, clamps and heater core from the vehicle.

graphic
Fig.1: 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. Install the heater core cover and attaching screws.

  3. Install the floor outlet and retaining screws.

  4. Install the instrument panel.

  5. Raise the vehicle and support it safely.

  6. Connect the heater hoses to the heater core.

  7. Carefully lower the vehicle.

  8. Fill the cooling system with the proper type and amount of coolant.

  9. Enable the SIR system.

  10. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level, and add if necessary.

Disable SIR :

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 (fuse 3) from the fuse block.

  4. Remove the steering column filler panel/left-hand sound insulator.

  5. Disengage the Connector Position Assurance (CPA) and the yellow 2-way connector, located near the base of the steering column.

  6. Connect the negative battery cable.

     

    ENABLING THE SYSTEM

    1. Disconnect the negative battery cable.

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

    3. Engage the yellow SIR connector and corresponding CPA located near the base of the steering column.

    4. Install the steering column filler panel/lower trim panel.

    5. Install the AIR BAG fuse (fuse 3) 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.

 


The following procedures are derived from repair procedures on the AutoZone website. Replacement parts, and much more information to help you maintain your vehicle is available on the AutoZone website.

Warnings & Precautions

Before servicing the vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

  • Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant.
  • All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.
  • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. 
  • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected.
  • Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.


JC Whitney - Truck, SUV, and Van

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