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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 657 (ENGINE MECHANICAL - 3.8L)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE FRONT COVER REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the engine front cover, install the camshaft position sensor to the engine front cover.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the camshaft position sensor bolt.

    Tighten 

    Tighten the bolt to 10 N.m (89 lb in).

    Fig 1: Installing Camshaft Position Sensor
    G02083613Courtesy of GENERAL MOTORS CORP.
  3. If replacing the engine front cover, install the oil pump cover and gear set to the engine front cover. Refer to OIL PUMP COVER AND GEAR SET REPLACEMENT  .
    Fig 2: Installing Oil Pump Cover And Gear Set To Engine Front Cover
    G02083614Courtesy of GENERAL MOTORS CORP.
  4. If replacing the engine front cover, install the water pump.
  5. Install and tighten the water pump bolts.

    Tighten 

    • Tighten the long water pump bolts to 34 N.m (25 lb ft).
    • Tighten the short water pump bolts to 22 N.m (16 lb ft).
    Fig 3: Installing Water Pump Bolts
    G02083615Courtesy of GENERAL MOTORS CORP.
  6. If replacing the engine front cover, install the pressure relief valve, the oil filter adapter and the oil filter adapter bolts to the engine front cover.

    Tighten 

    Tighten to 15 N.m (11 lb ft) + 50 degrees.

    Fig 4: Installing Pressure Relief Valve And Oil Filter Adapter
    G02083616Courtesy of GENERAL MOTORS CORP.
  7. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged.
  8. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads.
    Fig 5: Installing New Engine Front Cover Gasket
    G02083617Courtesy of GENERAL MOTORS CORP.
  9. Align the cogs on the crankshaft sprocket with the cogs on the oil pump gear set in the engine front cover.
  10. Install the engine front cover to the engine.
    Fig 6: Installing Engine Front Cover To Engine
    G02083618Courtesy of GENERAL MOTORS CORP.
  11. Install the engine front cover bolts (1-7).

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft) + 40 degrees.

    Fig 7: Installing Engine Front Cover Bolts
    G02083619Courtesy of GENERAL MOTORS CORP.
  12. Install the crankshaft position sensor.
  13. Install the crankshaft position sensor studs.

    Tighten 

    Tighten the studs to 30 N.m (22 lb ft).

  14. Install the oil pan-to-engine front cover bolts.

    Tighten 

    Tighten the oil pan bolts to 14 N.m (125 lb in).

  15. Install the oil level sensor.

    Tighten 

    Tighten the sensor to 20 N.m (15 lb ft).

  16. Connect the oil level sensor electrical connector.
  17. Install the engine mount bracket. Refer to ENGINE MOUNT AND BRACKET REPLACEMENT  .
    Fig 8: Installing Crankshaft Position Sensor
    G02083620Courtesy of GENERAL MOTORS CORP.
  18. Install the water pump pulley and bolts.

    Tighten 

    Tighten the bolts to 13 N.m (116 lb in).

  19. Install the radiator outlet hose to the water pump. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  20. Install the oil filter. Install the engine oil pan drain plug. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
    Fig 9: Installing Oil Filter
    G02083621Courtesy of GENERAL MOTORS CORP.
  21. Install the new engine front cover seal using J 35354  .
  22. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
  23. Remove the J 35354  .
    Fig 10: Installing Engine Front Cover Seal
    G02083622Courtesy of GENERAL MOTORS CORP.
  24. Install the crankshaft position sensor shield.
  25. Connect the electrical connectors to the following:
    • Oil pressure sensor
    • Crankshaft position (CKP) sensor
    • Camshaft position (CMP) sensor
  26. Install the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT  .
  27. Lower the vehicle.
    Fig 11: Installing Crankshaft Position Sensor Shield
    G02083623Courtesy of GENERAL MOTORS CORP.
  28. Install the power steering pump and the bolts.

    Tighten 

    Tighten the bolts to 34 N.m (25 lb ft).

  29. Remove the engine support fixture.
  30. Install the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT  .
  31. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  32. Fill the crankcase with engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  33. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  34. Inspect for leaks.
  35. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE in Engine Performance - Removal and Installation.
    Fig 12: Installing Power Steering Pump And Bolts
    G02083624Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.