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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) >> 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 vacuum hose from the water bypass valve.
    Fig 1: Removing Hot Water Bypass Valve
    G01645651Courtesy of GENERAL MOTORS CORP.
  5. Using the J 38185,  reposition the heater inlet pipe (5) clamp from the water bypass valve.
  6. Remove the heater inlet pipe from the water bypass valve.
  7. Using the J 38185,  reposition the heater outlet pipe (6) clamp from the water bypass valve.
  8. Remove the heater outlet pipe from the water bypass valve.
  9. Using the J 38185,  reposition the heater inlet hose clamp from the water bypass valve.
  10. Remove the heater inlet hose from the water bypass valve.
  11. Using the J 38185,  reposition the heater outlet hose clamp from the water bypass valve.
  12. Remove the heater outlet hose from the water bypass valve.
  13. Remove the bolt (3) that retains the water bypass valve (4) to the heater assembly.
  14. Remove the water bypass valve.
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