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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 648 (Engine Cooling System) >> Repair Instructions >> Coolant Heater 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. Drain the cooling system and the engine block.

    Refer to Draining & Filling Cooling System .

  2. Raise the vehicle.
  3. Remove the right front tire and wheel.
  4. Remove the right front fender wheelhouse inner fender (1).
    5. Fig 1: Right Front Fender Wheelhouse Inner Fender
    G01658216Courtesy of GENERAL MOTORS CORP.
  5. Remove the right engine mount.
  6. Disconnect the engine coolant heater cord.
    Fig 2: Engine Coolant Heater Cord
    G01658217Courtesy of GENERAL MOTORS CORP.
  7. Loosen the bolt retaining the engine coolant heater to the block.
  8. Remove the engine coolant heater from the engine block.
    9. Fig 3: Engine Coolant Heater
    G01658218Courtesy of GENERAL MOTORS CORP.
  9. Do not score the machined surface of the hole.
  10. Grasp the plug with pliers.
  11. Pull the plug from the engine block.
  12. Clean the core plug hole in order to remove the following substances:
    • Burrs
    • Compound
    • Paint
    • Rough spots
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