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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 688 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.6L Engine) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
    4. Fig 1: Upper Intake Manifold Cover
    G01658079Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the battery negative cable.
  5. Drain the engine coolant. Refer to Draining & Filling Cooling System .
  6. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or Fan Shroud Replacement - Upper (W/M74)  .
  7. Remove the drive belt.
  8. Disconnect the A/C compressor clutch electrical connector.
  9. Disconnect the A/C cut out switch electrical connector.
  10. Remove the A/C compressor mounting bolts.
  11. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
    Fig 2: A/C Compressor
    G01658080Courtesy of GENERAL MOTORS CORP.
  12. Remove the nut retaining the generator positive cable to the generator.
  13. Remove the positive cable from the generator.
  14. Remove the clip holding the positive cable to the engine front cover.
  15. Remove the bolt retaining the battery positive cable junction block to the power steering pump.
  16. Move the generator positive cable and the junction block bracket aside.
  17. Disconnect the generator electrical connector.
  18. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  19. Remove the power steering pump mounting bracket and secure to the side.
    • Do not remove the power steering pump from the bracket.
    • The hoses and battery cables can remain on the power steering pump.
      Fig 3: Power Steering Pump Mounting Bracket
      G01658082Courtesy of GENERAL MOTORS CORP.
  20. Remove the bolts retaining the fuel bleed valve and PCV oil separator bracket from the generator mounting bracket.
    Fig 4: Generator Mounting Bracket
    G01658083Courtesy of GENERAL MOTORS CORP.
  21. Remove the heater outlet hose bracket bolt from the generator bracket.
  22. Remove the ribbed idler pulley.
  23. Remove the generator mounting bracket and secure to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
    24. Fig 5: Generator Mounting Bracket
    G01658084Courtesy of GENERAL MOTORS CORP.
  24. Remove the oil fill tube.
  25. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L Engine) .
  26. Remove the bolt retaining the heater pipe to the fuel filter assembly.
  27. Remove the bolt retaining the heater pipe to the thermostat housing crossover.
    28. Fig 6: Heater Pipe To The Thermostat Housing Crossover
    G01658085Courtesy of GENERAL MOTORS CORP.
  28. Remove the heater pipe with O-ring seal from the crossover.
  29. Remove the hose and clamp from the turbocharger outlet coolant pipe to thermostat bypass pipe.
  30. Remove the fuel line bracket from the thermostat housing crossover.
    31. Fig 7: Fuel Line Bracket At Thermostat Housing Crossover
    G01658086Courtesy of GENERAL MOTORS CORP.
  31. Remove the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L Engine) .
  32. Remove the 2 thermostat housing crossover bolts and 2 nuts from the left cylinder head.
  33. Remove the 2 thermostat housing crossover bolts and 2 nuts from the right cylinder head.
  34. Remove the bypass pipe to water pump bolts.
  35. Remove the thermostat housing crossover with the bypass pipe.
    36. Fig 8: Thermostat Housing Crossover With Bypass Pipe
    G01658087Courtesy of GENERAL MOTORS CORP.
  36. Remove the bypass pipe to water pump O-ring.
  37. Remove the bypass pipe from the thermostat housing crossover.
  38. Remove the O-ring from the bypass pipe.
    Fig 9: Bypass Pipe O-Ring
    G01658088Courtesy of GENERAL MOTORS CORP.
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