LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1355 (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 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 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. Drain the cooling system. Refer to Draining and Filling Cooling System .
  5. Disconnect the negative battery cables. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or  BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY)  .
    Fig 1: Remove Upper Intake Manifold Cover
    G02109142Courtesy of GENERAL MOTORS CORP.
  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. Refer to DRIVE BELT ROUTING .
  8. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5).
  9. Disconnect the A/C cut out switch electrical connector.
    Fig 2: Disconnect A/C Compressor Clutch Electrical Connector
    G02109143Courtesy of GENERAL MOTORS CORP.
  10. Remove the A/C compressor bolts.
  11. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
    Fig 3: Remove A/C Compressor Bolts
    G02109144Courtesy of GENERAL MOTORS CORP.
  12. Remove the generator positive cable to generator nut.
  13. Remove the positive cable from the generator.
  14. Remove the clip holding the positive cable to the engine front cover.
  15. Remove the battery positive cable junction block to power steering pump bolt.
  16. Move the generator positive cable and the junction block bracket aside.
    Fig 4: Remove Generator Positive Cable To Generator Nut
    G02109145Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the generator electrical connector (1).
  18. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 5: Disconnect Generator Electrical Connector
    G02109146Courtesy of GENERAL MOTORS CORP.
  19. Remove the power steering pump 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 6: Remove Power Steering Pump Bracket
    G02109147Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel bleed valve and positive crankcase ventilation (PCV) oil separator bracket bolt from the generator bracket.
    Fig 7: Remove Fuel Bleed Valve & PCV Oil Separator Bracket Bolt
    G02109148Courtesy 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 bracket and position to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
  24. Remove the oil fill tube. Refer to OIL FILLER TUBE .
  25. Remove the water outlet. Refer to Water Outlet Tube Replacement (6.6L Engine) .
    Fig 8: Remove Heater Outlet Hose Bracket Bolt
    G02109149Courtesy of GENERAL MOTORS CORP.
  26. Remove the heater inlet pipe to fuel filter bolt.
  27. Remove the heater inlet pipe with O-ring seal from the crossover.
    Fig 9: Remove Heater Inlet Pipe & Bolt
    G02109150Courtesy of GENERAL MOTORS CORP.
  28. Remove the turbocharger coolant return pipe clamps and hose.
  29. Remove the fuel line bracket from the thermostat housing crossover.
  30. Remove the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L Engine) .
    Fig 10: Remove Fuel Line Bracket, Thermostat Coolant Return Pipe Clamps & Hose
    G02109151Courtesy of GENERAL MOTORS CORP.
  31. Remove the thermostat housing bolts and nuts from the left cylinder head.
  32. Remove the thermostat housing bolts and nuts from the right cylinder head.
  33. Remove the bypass pipe to water pump bolts.
  34. Remove the thermostat housing with the bypass pipe.
  35. Remove the bypass pipe to water pump O-ring.
    Fig 11: Remove Thermostat Housing Bolts & Nuts
    G02109152Courtesy of GENERAL MOTORS CORP.
  36. Remove the bypass pipe from the thermostat housing.
  37. Remove the O-ring from the bypass pipe.
    Fig 12: Remove Bypass Pipe & O-Ring
    G02109153Courtesy of GENERAL MOTORS CORP.
  38. Remove the thermostat cover bolts.
  39. Remove the thermostat cover.
  40. Remove the thermostats with seals.
  41. Remove the thermostat seals.
  42. If required, clean and inspect the thermostat housing.
    Fig 13: Remove Thermostat, Seals, Cover & Bolts
    G02109154Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals