Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPONTIAC2004AZTEK AWD V6-3.4L VIN EREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGHEATER CORESERVICE AND REPAIRHEATER CORE REPLACEMENT
2004 Pontiac Aztek AWD V6-3.4L VIN E
Heater Core Replacement
2004 Pontiac Aztek AWD V6-3.4L VIN ESECTION Heater Core Replacement
HEATER CORE REPLACEMENT (LA1)
TOOLS REQUIRED
J 38185 Hose Clamp Pliers
REMOVAL PROCEDURE
1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
2. Remove the wiper module.
3. Disconnect the brake booster vacuum hose and reposition.
4. Remove the air cleaner cover and intake tube.
IMPORTANT: Disconnect the throttle and cruise control cables from the TBI mounting bracket to prevent bending the cable housings.
5. Disconnect the throttle and cruise control cables.
6. Remove the transmission fluid filler tube.
7. Disconnect both of the heater hose clamps at the heater core using the J 38185.
8. Disconnect the heater hoses from the heater core.
IMPORTANT: Cap off the heater core inlet and outlet pipes to prevent coolant spillage inside of the vehicle.
9. Cap off the heater core pipes.
10. Remove the right I/P insulator.
11. Remove the left I/P insulator.
12. Remove the center floor air outlet.
13. Remove the screws retaining the heater outlet duct.
14. Remove the heater outlet duct.
15. Remove the I/P harness to heater core cover tie strap.
16. Remove the screws retaining the heater core cover.
17. Remove the heater core cover.
18. Remove the heater core pipe retaining screw.
19. Remove the heater core from the HVAC module.
INSTALLATION PROCEDURE
1. Install the heater core to the HVAC module case.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the heater core pipe retaining clamp screw.
Tighten
Tighten the screw to 0.9 N.m (8 lb in).
3. Install the heater core cover.
4. Install the heater core cover retaining screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
5. Install the heater outlet duct.
6. Install the heater outlet duct screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
7. Install the I/P harness to heater core cover tie strap.
8. Install the center floor air outlet.
9. Install the left I/P insulator.
10. Install the right I/P insulator.
11. Install the heater hoses to the heater core.
12. Connect the heater hose clamps using the J 38185.
13. Install the transmission fluid filler tube.
14. Install the air cleaner cover and intake hose.
15. Connect the throttle and cruise control cables to the TBI mounting bracket.
16. Connect the brake booster vacuum hose.
17. Install the wiper module.
18. Fill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
TOOLS REQUIRED
J 38185 Hose Clamp Pliers
REMOVAL PROCEDURE
1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
2. Remove the wiper module.
3. Disconnect the brake booster vacuum hose and reposition.
4. Remove the air cleaner cover and intake tube.
IMPORTANT: Disconnect the throttle and cruise control cables from the TBI mounting bracket to prevent bending the cable housings.
5. Disconnect the throttle and cruise control cables.
6. Remove the transmission fluid filler tube.
7. Disconnect both of the heater hose clamps at the heater core using the J 38185.
8. Disconnect the heater hoses from the heater core.
IMPORTANT: Cap off the heater core inlet and outlet pipes to prevent coolant spillage inside of the vehicle.
9. Cap off the heater core pipes.
10. Remove the right I/P insulator.
11. Remove the left I/P insulator.
12. Remove the center floor air outlet.
13. Remove the screws retaining the heater outlet duct.
14. Remove the heater outlet duct.
15. Remove the I/P harness to heater core cover tie strap.
16. Remove the screws retaining the heater core cover.
17. Remove the heater core cover.
18. Remove the heater core pipe retaining screw.
19. Remove the heater core from the HVAC module.
INSTALLATION PROCEDURE
1. Install the heater core to the HVAC module case.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the heater core pipe retaining clamp screw.
Tighten
Tighten the screw to 0.9 N.m (8 lb in).
3. Install the heater core cover.
4. Install the heater core cover retaining screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
5. Install the heater outlet duct.
6. Install the heater outlet duct screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
7. Install the I/P harness to heater core cover tie strap.
8. Install the center floor air outlet.
9. Install the left I/P insulator.
10. Install the right I/P insulator.
11. Install the heater hoses to the heater core.
12. Connect the heater hose clamps using the J 38185.
13. Install the transmission fluid filler tube.
14. Install the air cleaner cover and intake hose.
15. Connect the throttle and cruise control cables to the TBI mounting bracket.
16. Connect the brake booster vacuum hose.
17. Install the wiper module.
18. Fill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.