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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 802 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> Coolant Bypass Valve Replacement - Auxiliary >> 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. Remove the air cleaner. Refer to AIR CLEANER ASSEMBLY in Removal & Installation.
  2. Remove the upper fan shroud. Refer to FAN SHROUD REPLACEMENT - UPPER in Engine Cooling.
  3. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  4. Disconnect the electrical connector from the auxiliary coolant bypass valve (1).
  5. Remove the vacuum hose from the auxiliary coolant bypass valve.
  6. Remove the bolt that retains the auxiliary coolant bypass valve to the heater assembly.
  7. Using the J 38185,  reposition the auxiliary heater inlet hose (10) clamp from the auxiliary coolant bypass valve.
  8. Remove the auxiliary heater inlet hose (10) from the auxiliary coolant bypass valve.
  9. Using the J 38185,  reposition the auxiliary outlet heater hose (2) clamp from the auxiliary coolant bypass valve.
  10. Remove the auxiliary outlet heater hose (2) from the auxiliary coolant bypass valve.
  11. Remove the auxiliary coolant bypass valve (1).
    Fig 1: Removing Auxiliary Coolant Bypass Valve
    G01645677Courtesy of GENERAL MOTORS CORP.
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