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Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect both battery negative cables.
  2. Drain the coolant from the radiator. Refer to Draining and Filling Cooling System .
  3. Remove the air cleaner assembly from the vehicle. Refer to AIR CLEANER ASSEMBLY .
  4. Remove the air intake duct from the turbocharger.
    5. Fig 1: Removing Air Intake Duct
    G01699551Courtesy of GENERAL MOTORS CORP.
  5. Remove the nut securing the engine oil level indicator tube and the transmission fluid level tube at the thermostat housing.
  6. Remove the stud securing the fuel bleed valve at the thermostat housing.
  7. Remove the A/C compressor. Refer to COMPRESSOR .
  8. Disconnect the coolant temperature sensor electrical connector.
  9. Disconnect the heater hose at the thermostat housing crossover.
  10. Disconnect the by-pass hose at the thermostat housing crossover.
    Fig 2: Disconnecting By-Pass Hose
    G01699552Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the radiator inlet hose at the thermostat housing crossover.
    Fig 3: Disconnecting Radiator Inlet Hose
    G01699553Courtesy of GENERAL MOTORS CORP.
  12. Remove the studs and bolts securing the thermostat housing crossover to the engine.
  13. Remove the thermostat housing crossover.
  14. Clean the thermostat housing crossover sealing surfaces.
    Fig 4: Removing Studs & Bolts
    G01699554Courtesy of GENERAL MOTORS CORP.
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