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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 >> Water Crossover Replacement (8.1L 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. Refer to Draining & Filling Cooling System .
  2. Remove the drive belt tensioner.
  3. Reposition the inlet hose clamp at the water crossover.
  4. Remove the inlet hose from the water crossover.
    Fig 1: Inlet Hose From Water Crossover
    G01658102Courtesy of GENERAL MOTORS CORP.
  5. Reposition the heater inlet hose clamp at the water crossover.
  6. Remove the heater inlet hose from the water crossover.
    Fig 2: Heater Inlet Hose From Water Crossover
    G01658103Courtesy of GENERAL MOTORS CORP.
  7. Reposition the bypass hose clamps at the water crossover and water pump.
  8. Remove the bypass hose.
    Fig 3: Bypass Hose
    G01658104Courtesy of GENERAL MOTORS CORP.
  9. Remove the generator.
  10. Remove the power steering pump.
  11. Remove the generator bracket bolts and nut.
  12. Remove the generator bracket stud.
  13. Remove the generator bracket.
    Fig 4: Generator Bracket
    G01658105Courtesy of GENERAL MOTORS CORP.
  14. Remove the water crossover bolts.
  15. Remove the water crossover.
  16. Remove and discard the water crossover gaskets.
    Fig 5: Water Crossover
    G01658106Courtesy of GENERAL MOTORS CORP.
  17. If replacing the water crossover remove the following:
    1. 17.1. Water outlet bolts (2)
    2. 17.2. Water outlet (1)
    3. 17.3. Thermostat (3)
      Fig 6: Water Crossover & Thermostat
      G01658107Courtesy of GENERAL MOTORS CORP.
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