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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Cooling System) >> Repair Instructions >> Thermal Bypass Fitting Replacement (5.3L Engine w/RPO HP2) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Drain the cooling system and engine block. Refer to Draining and Filling Cooling System (with HP2) .
  3. If necessary, disconnect the crankshaft position (CKP) sensor electrical connector.
    4. Fig 1: View Of CKP Sensor Electrical Connector
    GM1236361Courtesy of GENERAL MOTORS CORP.
  4. Remove the thermal bypass hose bolt.
  5. Reposition the thermal bypass hose clamp.
  6. Remove the thermal bypass hose from the fitting.
    7. Fig 2: View Of Thermal Bypass Hose
    GM1195697Courtesy of GENERAL MOTORS CORP.
  7. Remove the thermal bypass fitting.
    8. Fig 3: View Of Thermal Bypass Fitting
    GM1195699Courtesy of GENERAL MOTORS CORP.
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