Heater Water Bypass Valve Replacement W/O C36

Tools Required

J 38185 Hose Clamp Pliers

1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.
2. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .



3. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Disconnect the vacuum hose from the water bypass valve.
5. Using the J 38185 , reposition the heater inlet pipe (5) clamp from the water bypass valve.
6. Remove the heater inlet pipe from the water bypass valve.
7. Using the J 38185 , reposition the heater outlet pipe (6) clamp from the water bypass valve.
8. Remove the heater outlet pipe from the water bypass valve.
9. Using the J 38185 , reposition the heater inlet hose clamp from the water bypass valve.
10. Remove the heater inlet hose from the water bypass valve.
11. Using the J 38185 , reposition the heater outlet hose clamp from the water bypass valve.
12. Remove the heater outlet hose from the water bypass valve.
13. Remove the bolt (3) that retains the water bypass valve (4) to the heater assembly.
14. Remove the water bypass valve.

1. Install the water bypass valve (4) to the heater assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolt (3) that retains the water bypass valve to the heater assembly.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

3. Install the heater outlet hose to the water bypass valve.
4. Using the J 38185 , reposition the heater outlet hose clamp to the water bypass valve.
5. Install the heater inlet hose to the water bypass valve.
6. Using the J 38185 , reposition the heater inlet hose clamp to the water bypass valve.
7. Install the heater outlet pipe to the water bypass valve.
8. Using the J 38185 , reposition the heater inlet pipe (5) clamp to the water bypass valve.
9. Install the heater inlet pipe to the water bypass valve.
10. Using the J 38185 , reposition the heater outlet pipe (6) clamp to the water bypass valve.
11. Connect the vacuum hose to the water bypass valve.
12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
13. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
14. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.

Heater Water Bypass Valve Replacement W/C36

Tools Required

J 38185 Hose Clamp Pliers

1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.
2. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .



3. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Disconnect the vacuum hose from the water bypass valve.
5. Using the J 38185 , reposition the heater inlet hose (8) clamp from the water bypass valve.
6. Remove the heater inlet hose (8) from the water bypass valve.
7. Using the J 38185 , reposition the heater outlet hose (7) clamp from the water bypass valve.
8. Remove the heater outlet hose (7) from the water bypass valve.
9. Using the J 38185 , reposition the heater inlet hose (3) clamp from the water bypass valve.
10. Remove the heater inlet hose (3) from the water bypass valve.
11. Using the J 38185 , reposition the heater outlet hose (4) clamp from the water bypass valve.
12. Remove the heater outlet hose (4) from the water bypass valve.
13. Using the J 38185 , reposition the auxiliary heater outlet hose clamp from the water bypass valve.
14. Remove the auxiliary heater outlet hose (5) from the water bypass valve.
15. Using the J 38185 , reposition the auxiliary heater outlet hose clamp (6) from the water bypass valve.
16. Remove the auxiliary heater outlet hose (10) from the water bypass valve.
17. Remove the bolt that retains the water bypass valve to the heater assembly.
18. Remove the water bypass valve.

1. Install the water bypass valve to the heater assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolt (3) that retains the water bypass valve to the heater assembly.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

3. Install the auxiliary heater outlet hose (5) to the water bypass valve.
4. Using the J 38185 , reposition the auxiliary heater outlet hose clamp to the water bypass valve.
5. Install the auxiliary heater outlet hose (10) to the water bypass valve.
6. Using the J 38185 , reposition the auxiliary heater outlet hose clamp (6) to the water bypass valve.
7. Install the heater outlet hose (4) to the water bypass valve.
8. Using the J 38185 , reposition the heater outlet hose clamp to the water bypass valve.
9. Install the heater inlet hose (3) to the water bypass valve.
10. Using the J 38185 , reposition the heater inlet hose clamp to the water bypass valve.
11. Install the heater outlet hose (7) to the water bypass valve.
12. Using the J 38185 , reposition the heater inlet hose clamp to the water bypass valve.
13. Install the heater inlet hose (8) to the water bypass valve.
14. Using the J 38185 , reposition the heater outlet hose clamp to the water bypass valve.
15. Connect the vacuum hose to the water bypass valve.
16. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
17. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
18. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.3L.