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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 798 (Engine Cooling System) >> Repair Instructions >> Coolant Heater Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
  2. If not originally equipped with an engine coolant heater, remove the coolant jacket plug by using the following procedure.
    1. 2.1. Carefully tap the coolant jacket plug near the outer edge. This causes the plug to rotate in the hole.

      Do not score the machined surface of the hole.

    2. 2.2. Grasp the plug with pliers and pull the plug out.
  3. Remove the cord from the engine coolant heater.
    Fig 1: Identifying Heater Cord Connection At Core Plug
    G01646448Courtesy of GENERAL MOTORS CORP.
  4. Loosen the bolt.
  5. Remove the engine coolant heater.
  6. Clean the core plug hole. Remove any of the following conditions
    • Burrs
    • Compound
    • Paint
    • Rough spots
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