Pontiac Repair: Heater core for a 2000 pontiac montana, fastener torque, pontiac montana

Question
I am trying to replace the heater core for my 2000 pontiac montana.  I have taken almost the entire lower dash out and still cannot get the cover off.  Are there any easy ways to do this?

Answer
Hi Allen:

Here is the complete procedure right out of our service manual. This is a really tough job. It's been a long time since I did one I remeber it reallt sucked to do.

Heater Core Cover Replacement
Removal Procedure
Remove the right instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Right in Instrument Panel, Gauges and Console.
Remove the left instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Console.
Remove the lower center console. Refer to Console Replacement - Front Floor in Instrument Panel, Gauges and Console.
Remove the console bracket. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gauges and Console.
Remove the floor duct brace
Remove the floor duct



Remove the screws retaining the heater core outlet cover.
Remove the heater core outlet cover.



Remove the screws retaining the heater core cover.
Remove the heater core cover.
Installation Procedure




Install the heater core cover.
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.

Install the heater core cover retaining screws.

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





Install the heater core outlet cover.
Install the heater core outlet cover retaining screws.

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

Install the floor duct.
Install the floor duct brace.
Install the floor duct brace retaining nuts.

Tighten
Tighten the nuts to 10 N·m ( 89 lb in).

Install the console bracket. Refer to Bracket Replacement - Console Floor in Instrument Panel, Gauges and Console.
Install the lower center console. Refer to Console Replacement - Front Floor in Instrument Panel, Gauges and Console.
Install the left instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Console.
Install the right instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Right in Instrument Panel, Gauges and Console.
There are pictures that go along with this but For some reason I can't cut and paste them into this. Good luck :}