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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different car >> Section 412 (Engine Cooling System) >> Repair Instructions >> Coolant Crossover Pipe Replacement (8.1L Engine) >> Removal Procedure

Removal Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 GMC Yukon XL, 2004 GMC Yukon, 2004 Chevrolet Tahoe, 2004 Chevrolet Suburban, and 2004 Cadillac Escalade EXT. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Inlet Hose Clamp & Water Crossover
    GM751425Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System .
  2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement - Accessory in Engine Mechanical - 8.1 L.
  3. Position the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
    5. Fig 2: View Of Heater Inlet Hose At Water Crossover (8.1L)
    GM750694Courtesy of GENERAL MOTORS CORP.
  5. Position the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
    7. Fig 3: View Of Bypass Hose (8.1L)
    GM846662Courtesy of GENERAL MOTORS CORP.
  7. Position the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
    9. Fig 4: View Of Generator Bracket, Bolts, Nut & Stud
    GM751458Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator. Refer to Generator Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (8.1L Engine) in Engine Electrical.
  10. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L and 6.0L) or Power Steering Pump Replacement (8.1L) in Power Steering System.
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
    14. Fig 5: View Of Engine Coolant Crossover & Gasket
    GM470698Courtesy of GENERAL MOTORS CORP.
  14. Remove the water crossover bolts.
  15. Remove the water crossover.
  16. Remove and discard the water crossover gaskets.
    17. Fig 6: View Of Water Outlet, Bolts & Thermostat
    GM635643Courtesy of GENERAL MOTORS CORP.
  17. If replacing the water crossover remove the following:
    1. Water outlet bolts (2)
    2. Water outlet (1)
    3. Thermostat (3)
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