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Home >> Chevrolet >> 2001 >> Impala Base, 3.8 K >> Repair and Diagnosis >> External Pages >> Different car >> Section 449 (Engine Cooling System) >> Repair Instructions >> Water Crossover Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Intrigue, 2001 Oldsmobile Intrigue, and 2000 Oldsmobile Intrigue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System .
  3. Remove the air cleaner assembly.
  4. Remove the throttle body. Refer to THROTTLE BODY in Engine Performance.
  5. Remove the EGR outlet pipe.
  6. If equipped with AIR, remove the bank 2 secondary air injection shut-off valve and the bracket. Refer to REMOVAL & INSTALLATION (3.5L -- BANK 2) in Engine Controls - 3.5L.
  7. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE in Engine Mechanical - 3.5L.
  8. Raise and support the vehicle.
  9. Remove the transmission filler tube. Refer to FLUID FILLER TUBE in Automatic Transaxle - 4T65 - E.
  10. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  11. Remove the EGR inlet pipe from the right exhaust manifold.
  12. Remove the frame assembly. Refer to FRAME REPLACEMENT in Transmission.
  13. If equipped with AIR, remove the AIR crossover pipe bolt (3).
  14. If equipped with AIR, remove the AIR crossover pipe nut.

    Important:  DO NOT remove the right exhaust manifold from the vehicle.

  15. Remove the right exhaust manifold from the right cylinder head and the left exhaust manifold. Position the manifold aside. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT in Engine Exhaust.
  16. Lower the vehicle.
  17. Remove the EGR valve and the EGR heat shield. Refer to EGR VALVE in Engine Performance.
  18. Remove the radiator inlet hose from the coolant crossover. Refer to Radiator Hose Replacement - Inlet .
  19. Remove the heater inlet hose from the coolant crossover.
  20. Remove the throttle body coolant hose from the coolant crossover.
  21. Remove the coolant crossover bolts (1-6).
    Fig 1: Remove AIR Crossover Pipe Bolt And Nut
    G01758025Courtesy of GENERAL MOTORS CORP.
    Fig 2: Remove Coolant Crossover Bolts
    G01758026Courtesy of GENERAL MOTORS CORP.
  22. Remove the coolant crossover.
  23. Remove the coolant crossover gaskets.
  24. Clean and inspect the coolant crossover gasket mating surfaces.
    Fig 3: Remove Coolant Crossover
    G01758027Courtesy of GENERAL MOTORS CORP.
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