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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 >> Hot Water Bypass Valve Replacement (W/O C36) >> Installation Procedure

Installation 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. Install the water bypass valve (4) to the heater assembly.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    Fig 1: Installing Hot Water Bypass Valve
    G01645652Courtesy of GENERAL MOTORS CORP.
  2. Install the bolt (3) that retains the water bypass valve to the heater assembly.

    Tighten 

    Tighten the bolt to 4 N.m (35 lb in).

  3. Install the heater outlet hose to the water bypass valve.
  4. Using the J 38185,  reposition the heater outlet hose clamp to the water bypass valve.
  5. Install the heater inlet hose to the water bypass valve.
  6. Using the J 38185,  reposition the heater inlet hose clamp to the water bypass valve.
  7. Install the heater outlet pipe to the water bypass valve.
  8. Using the J 38185,  reposition the heater inlet pipe (5) clamp to the water bypass valve.
  9. Install the heater inlet pipe to the water bypass valve.
  10. Using the J 38185,  reposition the heater outlet pipe (6) clamp to the water bypass valve.
  11. Connect the vacuum hose to the water bypass valve.
  12. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  13. Install the upper fan shroud. Refer to FAN SHROUD REPLACEMENT - UPPER in Engine Cooling.
  14. Install the air cleaner. Refer to AIR CLEANER ASSEMBLY in Removal & Installation.
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